27 - Spindles

7/23/2019 27 - Spindles

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7/23/2019 27 - Spindles


. . . l ' $.exus Special Interes'ts Ltd .

Nexus HouseBoundary W ayHemel HempsteadHertfordshire HP2 7STEngland

First published 1 997

@ Text and illustrations Harprit Sandhu 1 997

ISBN 1-85486-149-2

AII rights reserved. No part of this publication m ay bereproduced in any form , by print, photography, m icrofilmor any other m eans w ithout w ritten permission fromthe publisher.

Typeset by Kate W illiam s, London .

Printed and bound in Great Britain by Biddles Ltd ., Guildford and King's Lynn.

Conients

1 lntroduction2 Designing a spindle3 The basic spindle4 M ounting the spindle5 A sm aller No 2 M orse taper spindle6 The m icro spindle

7 1 .000 inch diam eter spindle (25m m)8 1 .250 inch diam eter spindle (32mm)9 Light, tool-post OD grinding spindle

10 Light, tool-post m ounted ID grinding spindle1 .500 inch diameter (38m m)

1 1 Sim ple No 1 M orse taper spindle1 2 Vertical spindle or gear cutting fram e13 A spindle with tapered roller bearings14 Driving the spindles1 5 Notes on using the spindles

1 6 Notes and ancillary inform ation

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APPENDIX 1 SI drawingsAPPENDIX 2 UK equivalent tablesIndex

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CH A PTER 1

Introduction

*'

This is a book about m aking auxiliary m ill- will give years of service in the dirtiesting and grinding spindles for use w ith a environm ents imaginable but rather theysm all Iathe. Although the experienced are designed to be spindles that are easyengineer m ight pick up a trick or tw o, the to make and use in the am ateur's w ork-book is aim ed primarily at beginners. AII shop. I have made every attem pt to keepthe spindles can be made in the am ateur the number of com ponents needed toengineer's w orkshop by anyone w ith make any spindle to an absolute m ini-average machining skills. The spindles m um . l have tried to minim ise the needare described for m aking on and use with for sophisticated equipm ent as w ell as

the Myford Super 7B Iathe, however they the need for highly skilled work. Ofcan be adapted for use with other Iathes necessity, alI the splndles are of one ofw ith relative ease. two baslc designs, each being easy to

The spindles range in size from 0.750 follow .inches (1 9.O5m m) in diam eter to 2.250 Keeping the designs simple meant thatinches (57.1 5m m ) in diameter and are the spindles hadko be of one or two basicsuitable for a variety of purposes. A designs. In one design, two bearings arenovel design for a gear cutting fram e that used at the front end and the back bear-uses sealed ball bearings at each end is ing is free to move in the housing. Bothalso included. inside and outside races are clam ped on

The book provides the novice am ateur the front bearings and only the inner raceengineer w ith a ready source of inform a- is clamped on the back bearing. ln the'tion and discussion about the construc- second design, only one bearing is used

tion of som e of the various types of spin- at each end but both the inner and outerdles that are needed by the am ateur from races of each bearing are clam ped ortim e to tim e. W herever appropriate I glued. The second design w as slightlyhave given reasons behind the decisions harder to build in that it was a Iittle m oremade to help give the builder more confi- difficult to get the spacers just right.dence in his or her decision to make any How ever, you get a spindle w ith Iessm odifications for experim entation. axial play in the bearings. Since aII

These spindles are not intended to be spindles can be m ade to either design,industrial grade , heavy duty spindles that you have a choice as to which design you

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decide to use on your spindle. You can The m icro spindle w as m y effort at are available, for a sm all charge, from detail. Alhough this spindle m ight be a Iit-also com bine features from both designs designing the sm allest possible spindle Nexus Special Interests Books, Nexus tIe Iarger than what you had in m ind, it isinto the spindle you m ake. (Spindles w ith w ith ball bearings. This has an outside House, Boundary W ay, Hemel Hemp- very versatile. M odify the spindle nose toglued in bearings are a form of clamped diameter of 0.750 inches (20mm) and stead, Herts HP2 7ST. These drawings suit your lathe and the accessories thatbearing spindles.) the body is 4.000 inches (1O0m m ) Iong. are on A4 paper and are available in either you have at hand if you are not the lucky

Since the usefulness of a spindle is Here again I desijned with the Dremel imperial or SI dimensions. owner of a Myford Super 78 Iathe.completely dependent on the accessories M oto accessories ln m ind as a resource. The spindles are designed to be built on Other spindles offerspecial advantagesthat can be used w ith it, I have used This is a spindle m ore suited to the m any a sm all lathe w ith a m inim al need for m ill- that are needed under special circum -standard lathe nose threads and tapers lathes that are sm aller than the Myford ing operations. M ost of the w ork l carried stances or are better suited to sm allerwhen possible so that aII the standard Super 7. Since I do not have access to out w as done on a M yford Super 7 with Iathes orto special setups.Iathe accessories and other standard one of these Iathes, and have never used the average com plem ent of accessories. I If you decide to m ake any of the othercomponents can be used with these spin- one, I was unable to offer a design for a did use a 5.000 inch (10.000 inch in the spindles, first read Chapter 3 a couple ofdles. In particular I used the M yford spindle m ounting that l had actually built USA) South Bend Iathe to do the heavy tim es to get the principles and tech-Super 7 spindle nose standard with the and used. ln other areas I have presented work when a Iot of m aterial had to be niques described w ell in m ind. It w ill be aNo 2 MT (Morse taper) on the cartridge som e ideas that will be useful to the more removed. How ever, alI this work could trem endous help to you in building yourspindle in Chapter 3. This will allow you resourceful amateurs. have been done on the Myford Super 7. spindle, especially if you are a beginner.to use aII the tapers, collets, collet clos- I have also included a couple of designs M uch of the succqss ln making any- I could not resist Iooking into w hat w asers, m ill holders and chucks that are for which essentially only the draw ings thing is not sim piy a matter of having a needed to m ake a spindle w ith taperedavailable for use with this standard spin- are included. The construction of these set of drawings for the project but also bearings. The design that I came uq withdIe nose. The use of the No 2 M T, w hich spindles is very sim ilar to the construc- has to do w ith knowing how to m ake the is provided for your consideratlon inallows a % inch shaft to be held very tion of the other spindles in the book so setups and in which sequence to do the Chapter 13. If you first build the 2.250accurately, m akes it m uch easier to m ake the repetition of the instructions is work so that it turns out right. I have inch diameter spindle and then decide to

b for clock cutters etc. because avoided by doing this. m ade an attem pt to show the w ay in aII build this spindle it w ill be w orth yourr orsh bors can now be made with I have avoided using any exotic materi- these projects. Both setups and se- while to make it 2.250 inches in diam eter ese ar

straight shanks and held accurately w ith aIs altogether and every com ponent and quences w ith the reasons for using them also so that you do not have to m akerelative ease. all the raw materials should be readily are provided. These are especially critical another set of mounting jlates. My spin-

In the sm all grinding spindle I consid- available on either side of the Atlantic. l in the construction of spindles that are in- dIe is 2.000 inches in dlam eter to testered it best if the many arbor mounted have recommended the use of free tended to be high-speed qrecision tools. I how small a taper bearing spindle couldgrinding wheels, cutters and arbors as machining materials throughout. These tnave tried to show the bullder how the in- be. Going to 2.250 inches will allow thewell as the collets and collet closers that materials are easy to use, their m achin- herent properties of the Iathe and the use of slightly Iarger bearings and a 1are available for the ubiquitous Drem el ability is equivalent to that of brass. They standard com ponents provided by the inch diam eter for the internal spindle atMoto Tool (w idely available, but in case are m ore than strong enough for the manufacturer can be used to their best the bearings.of difficulty contact Microflame Ltd, ajplications that we have in mind. Their advantage in building these projects. AII the information and drawings need-Vinces Road, Diss, Norfolk, 1P22 3HQ; sllghtly higher cost will be m ore than paid The bearings used can be a m ixed bag ed to allow construction of the spindlesTel. 01 379 64481 3) were able to be for by the added pleasure of using these of metric and imperial sized bearings. ln are included in the book. Materials need-used w ith this spindle, These w heels are materials. I have avoided the use of general the sizes are not critical and ed to m ake the spindles are readily avail-very inexpensive and serve the needs of exotic tooling except for the use of the whatever is available in your area can be able and every attem pt has been made to

the am ateur engineer w ell. Here m y m ain ream ers for the M orse tapers. These used by changing a few dim ensions. m ake sure that nothing that is hard to getinterest was to have the ability to grind ream ers simplify making these tapers to W ith reference to the cartridge spindle is included in the projects.small parts and tools for projects Iike the point that not using them would be in Chajter 3: if you have a Myford Super I built only those items for which thereclock arbors, pinions and other sm all counter productive. Since these are not 7 or slm ilar Iathe and you are going to are photographs. If you do not have aparts with precision. This spindle w ill also tools that you need every day, it m ight be make only one general-purpose spindle photograph for reference you need toallow the making of sm all precision cut- possible to arrange to share with other for your shop, this is the one that you w ill exercise more caution w hen building inters that are often needed by the amateur amateur engineers. want to consider making. It gives you the that there is a slightly hijher possibilityengineer. W ith a little care and patience, For those who prefer to work from full- greatest versatility of aIl the spindles in of errors in the dim enslons given forit could also be used to grind fine threads. sized, formal engineering draw ings, these the book and is described in the greatest these designs. I did not build any spin-

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dles to m etric dim ensions so extra cau-' ' ded w ith these draw ings also L 'lon ls nee

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would appreciate it if the 'nform ationb forw arded to m e so that l can The S/'X spindlen made b/ me 1t7 VerifY theould e

. construction methods describedin the book.ake the necessary correctlons as soon. .

' I f r the benefit of future am a- Inïllrovementshave been 'DcorptvateEf/rlr/s posslb e o.

. . the dra wlngs.eur englneers and experlm enters whobuild these spindles .

Good Iuck and happy turning . E-m ail: Rhinorobot aol xcomïpar .p.Facsim ile: 2 1 7 -356- 6 944 J' b' , 'Telephone: 2 1 7-35 6-9300

Harprit Sandhu (Answering machine on 24 hours a day)C ham paig n I Ilinois . U SA Snailm ail: H S Sandhu , 7 O 5 est Ki rby

Decem ber 1 996 Avenue, Champaign, lllinois 6 1 820, USA

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4

CH A PTER 2

D esigning a spindle

This chapter contains a very short tuto-rial/discussion on the design of the spin-dles in the book. (This is very rnuch asim plified approach and no considerationis jiven to the making of calculationswhlch are a must in any serious effort.)

The basic idea is that there is nothingdifficult about designing a sim ple m a-chine if one goes about it in a m ethodicalway. The ideas presented are applicableto any basic design project.

The facts before us in this particularcase are as follow s:

w ill put the machine to. These are1he purposes for w hich the m achineis being designed.

* The ideas on w hich we are going tofocus have to do with designinjspindles for use by the am ateur engl-neering com m unity. These spindlesw ill be used for a variety of pur-poses, the m ain ones being light m ill-ing and grinding applications.

* The best and m ost popular am ateur'slathe on the m arket is the M yfordSuper 7B. At the risk of sounding IikeI have Iost m y m ind early in the gam e,I will say that no other manufacturereven com es close to providing such agood Iathe. For this reason we willdesign for this Iathe.

* M ost am ateur engineers, in general,and in spite of som e evidence to thecontrary, do not have a Iot of m oneyto spend on their hobbies.

* Before there is a spindle, there aredraw ings. It is m uch easier to w orkfrom a drawing that has been care-fully thought out.

* Before there are any draw ings, therew ill have been som e sketches. W ehave to m ake sketches and w ork outthe dim ensions and positional rela-tionships before w e can m ake theform al drawings.

* Before there are any sketches, therem ust have been som e ideas. Neitherdo sketches have a Iife of their own.They are expressions of ideas thatwe have about the m achine that wethinking about m aking w hich in turnare determ ined by the uses that we

It is always a good idea to keep track ofw hat you are thinking about by w riting itdown, so tet us Iist our conclusions.

W ith the above facts in m ind w e com eto the follow ing conclusions:

@ W e will design relatively sm all spin-dles.

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. They will be mounted on sealed ball which is a.1 25 inches (79.35m m) on as we can miss the spindle bearings). the equipment at our disposal that doesbearings. centre. The larger spindles w ill have to have not seem to be Iikely, so I am aoinc to

. They will be belt driven. So the mounting grid looks Iike Figure the studs straddle the spindle as shown suggest that we clamp only th'e i'ner

. w e w ill design for m ounting to the 2.1 . W e w ill start by placing critical com - in Figure 2.3. This takes up m ore room race of the back bearing and Iet the outerMyford s7 tables and slides etc. ponents on the grid. At this stage we are but also gives us m ore space to work race slide back and forth in the housina

. we will accommodate the use of working with sketches although I am with. If you analyse the Ioading on the spin Zleford accessories w hen possible. showing these as draw ings in the book. Now that we know where the spindle you will see that the axial load on they

. w e will design to allow versatility of If we are going to use the Myford nose is with respect to the mounting back bearing is minimal. Its major pur-use. accessories with this spindle, we need to studs, we can think about placing our pose is to provide radial support for the

. w e will keep costs down. use the same spindle nose as the Myford bearings to miss the studs. W e need two back end of the spindle. (There are other

. w e w ill keep down the skill Ievel uses. Let us assum e a 2.000 inch diam - bearings, one in the front and one in the w ays to control the distance betw eenneeded to build. eter spindle w ith a M yford spindle nose back. The front bearing is m ore critical the outer and inner recess of the bearings

. w e will Iim it the tim e needed to at one end and a pulley at the other end. because it is the one that bears m ost of and som e of these are show n in otherbuild. W e w ill represent aII this w ith sim ple rec- the Ioad and for this reason it should be designs in the book.)

. w e w ill not use exotic m aterials be- tangles in our sketches. as close to the cutter as possible. W ith The concepts presented above are. cause they are expensive and hard to Now Iet us position our spindle sketch this in m ind w e w ill try to place the front show n in Figure 2.5. Keep in m ind that

find. on the grid. Our spindle can be positioned bearing as far forw ard as we can and this is where we clam p the races. The'

., . to use either a single grid spacinj or a position the smaller rear bearing as is races are held at their OD by the housingThe M yford mounting slots are 1 .562 double spacing as the conditions dlctate. convenient. and at their ID by the spindle so these di-

inches (39.67mm) on centre and are suit- The next two figures show where the Let us place some bearings in the spin- rections will be properly constrained if weable for hold dow n studs that are 0.250 spindle w ould be in regard to the grid for turnthespindle partsto closedim ensions.inches (6.a5m m) in diameter. This tells each of these mountings. Each set of arrows represents a clam p-us that the spindle has to fit on a grid The smaller spindles will be able to U O O (3> ing device. We need three clamps or

nuts. The other side from each nut w ill be 562 inches (39.67m m) on centre. Our make use of the type of mounting shownm ounting bolts will be either 1 .562 in Figure 2.2 even if the studs have to be either the body of the housing or theinches (39.67mm) on centre ortwicethat within the housing of the spindle (as long z Z O O ; .

' 1.x2 inczes o C) o Figure 2.4 Bearings. smhdle. pullev andhole :ruoadded.

r ,ï( , O ()) (3 dIe to see how they Iook for position. ., j ,,w jnojxs ,

, . , . In a m illing spindle, most of the load is . Figure 2.2 Mountl'g the sgvwtwe on short taken up by the front bearings .

Industrial Figure 2.5 Thepoints where thebeanngs.

, . wtwge cyaswes. vjte (ssxe vearygs arejustpaong. milling machines often use three and four . . . .

b in s to ether very close to the nose .*n WO& *t '/và t'me 00 OX#/Or/ theposslbllitles. , , ear g q

. C) :) $:3 W e w ill use Just one in our design . At this. stage the basic concepts are in place

. and we are ready to w ork out the details .

. . . o o o How w e hold the bearings w ill be criti-g - cal. The front bearings m ust be integral

with the spindle . This m eans that both562 inches=39.675 mm .o c) .' the outer and inner races have to beo

'd forM vford s7 Clam ped tight to the housing and spindleigure 2 . 1 M ountlïw gntables. Studs are 1.562 inches (39.67mm) Fîgure 2.3 M ountl'g the spht//e for Iong resgectively. It w ill be best if the back Figure 2 . 6 The pcvhrs where the nuts -/'// be

?? b0th dlkections. spaoïw. . . .bearing is positioned exactly but , with used.n centre ,

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the chucks etc. A quick Iook at the bear- betw een inch and m etric dim ensions . tions resulted in the selection clamping elem ents to assure ourselves consldera. ing catalogues confirm ed that the spindle with the press of a buttonl.Since l am not bearings specified above. M any that there w ill be no rubbing betw een the

. of the .esign could be accomm odated within a used to metric dimenslons, I w as able to bearings could have been used . Do clamps and the bearlng seals. M ost bear-. other ..250 inch (65m m) diam eter spindle convert to Inches whenever needed to jet the availability of bearing put you Ing seals are below the Ievel of the races. . . . . notousing w ith a Iittle w ork. Thls Iarge spln- conflrm that I was In the ball park. l just bearing that you can get your but we m ust m ake sure . e also w ant toff - anY . .le diameter (to accomm odate the No 2 don't feel at hom e with exactly how (js on can be used . m ake sure tha't sw arf does not flnd Its

. . . hanT) Iead s to the need for heavler bear- m uch 7m m Is but Iam qulte com fortable nearings are m ade in m ore forms than w ay into the space created and eventu-ings, w hich f ortunately, are desirable in a w ith 0 .27 55 inches . jm agine . Our interest is in bear- ally ruin the seals .ou can

.m illing spindle. r. ' .' . s that are designed for axial Ioads and hen you are converting from m etrlcIr1 () . . . . .he spindle I m ade uses inch m aterials Bearings chosen ' ' . , d-al loads . Axial Ioads are along the to inch dlm enslons and vlce versa, It ISa.. . . ...

, u. u. .nd m etric bearings bOCaUSe that 's the ' axis . ln otlr case We mtlst have sealed wortn wrltlng uown tne tnlrd and f urthhOW it W orked OlX at 'th's time To sim- Nose end bearings ' : ' bearings to avo'd having to f it Seals . decim al places in the conversionsIify matters, the designs presented in Ntlm ber required 2 ' , oeep groove bearings f itted blp back to because they give an indication Of the f it7

the book use either aII 'mperial dimen- lnside diam eter 1 .000 in (25m m) back (double) or angular contact bearings that we will be expecting . In close f itss'ons Of all Sl dimensions lsee Appendix Outside d'am eter 2.000 in (5Om m) ith seals w ill be the best bet. Special 0.0005 inches can m ake a big dif fer-1 for SI draw ings) . l intend to explain the idth . 0.375 in (1 Omm) bearings to be used back to back are sold ence, Knowing whether is it going to bereason for using the dim ensions that I Seals Both sides . airs and glound to be a perfect pair loose or tight is a help.n p

. . w henever applicable. lncidentally Shields None The are how ever more expensive and ' '' ' '?se . y . ,the new digita calipers are a real conven- Type Deep grove bearings integral seals are often not available . W e Spindle parts 11stience in that they allow you to change w ith axial and radial will use the back bearing only to hold the The follow ing items are needed for 'the

load capability back of the spindle in the m iddle of the spindle'. .- .$ . E u-,.wusox . v ssîty . - s . . A j t e r n a e A n u I a r c o n t c t b e r h o u s - n g I c a r r - e s n o c u t - n g l o a d a x - a l l y '.v = g

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''ace Of tbis bearing is f ee (but tight) to .:>)'7ï:'l''' ,'>? .' t'7*rht' ,v'' ,7?#',' ??J.z,:k?:. ' ' j.,:t ,r' ,t,y.?y,,?,;,?,ky,,:,t,: ,i,$,,,kj,,,,,y ,jt.y ko . rnove axially in the housing . Alrnost aII Fron't bearlngs ' 2 purchasedt? ',pë',:J,;t: .;;?, $t:?r ,à.?,, @,, t.î s k,).r ,, j j,k h ,,, , j y,, y, j j. . . .

aear bearing ' . ' 1 purchased'.'t',. . .C ?ù, ttl o z ?,, )ë,,u?sty ttyrkr , jvjvyjvgtk uurnber requtred ' :he cuttlng load w1ll be taken by the palr . 't' 7'p:ëtyèg)?;ièj:jy/:lti 7.L. j j jj, $.yt.. jy; ,,yy,:j.t ,g. 'yt uy. )' j': y.. j?i/. t' )s' '(. ; :js.L ..) .)'tytt lzk..;

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bltl'cttt )t s,tn:k l.Ati j .tk ': st t .tt f tty ltsi' tjitst. Et 7lyp yjt.tjhysy,ojy yy klg lj.l jnyy ? .y s d je jlousl ng 1 .lt j.jlljt :yl) 4$';t.)?) ;?J )yrrj.,)lJy'Jtr $??k?k#r )): ?k j r f ,:. ,ly:,; t i .k.tj) tj jyst) j (yjx..t (y)uts i d d 1 a l'n ete r 1 . 7 50 1 n S e a e b a ri n g s a re 1 u b ri c at e d f r l e ? ' Ryzg.ftj gljytjytz jo:ytv :.t, è ,Jj.C ?#s.)(/ t rk yyja jyj.'ij : tj tyjyqrs j). f.. . ,s' t'ltlr L)((Lt ,.1 .' ;.:Vt;')q() ytnhliëîft-sftlsf)T 3yy ) $ ptyjh.g/urx . . c ap f r f ro n't bea rl ngs 1 :hiy.l Itl ltk.,i qdjt'' hzqji4 y.l1: #f#E# Tykjqjintyt i/j:yl ttjy rrjlvtjyty Idth 0 37 5 I n a nd need no atte nti o n to a ny f rth e r ')):Vt i:, tytrtfj. kl sktft j.) ()?fL s:/ti??)?tïàJyy:$j ;)$) ;)t$ y.) $t,yy 4? . . . x ut f r the pu I Iey 1 pu rchasedL?i'nry yryt :yj? :s Jt,yij.ti tjtttr ?.tj yjskljbktryylojj; y) jsy seajs 80th sldes Iu brlcation. Flow ever the seals rnust be .j kl/y ).#j.)lps?k . . #.s y J: L,I j i$.$ ) t j; L. tt êt qjiqjj ty; )t ,tjqc? jyy- . /:)t . thkttljdt n,nt'j t.t i ) J))i:):) . ;.blntjitiv:i? yi pyy L . . N ut to cl n'1 p f o n't be arI ngs 1:i; ' t):. jlp:yy/y ' y$:k ? 'zL tyyll tk ylt: t;))'k f:)) jtls) k s S h I e I d N o n e p tecte f o rn s w a rf a n d d I rtotk):r::' ':)' tttt . v-,' t ,(J:. ?.4j),?t kJkk$.:'yy L i/J jnjjyysyt) y o e p g ro ove be a ri g Taper beari n gs are best f o r heavy Ioadsb '$'t jj) .jà tkyp ltft f ) 't .r.;,y .:. '; $ , s'''

'.è.; ;k.( @ )gj.àrTt j) );, F t. 11// 1;:).4E5, 1:Lti t.).:takmk:l ':' / , j f:r îtjkLLtàt?tkfs Lkjbî tàqj,rttL uk) A jternate standard Ioad bearing but are a bit m ore dif f icult to use in a K0X StOCQ fOr ptllley 1 brass scrapj)?j y ? ipiftl sql.7 ;) )Jil ) ( J&:. Jt.l .j ::yytj j i q y tyy yyt; . j.j jo y,o p j.j lwbllq:r')).t t x'iuf.j.ri yjâtr jyywls j )jy cr.# p . . . . . . s p l It bu sjqh%j ?9/tp& ,0 pif 'ty:> l;t.ultzjyt? y'yjyjljsfyi (No te : the axI a 1 l o ad o n the bea rl g l s sp I nd Ie that 1 s both I n ex pe n s ive a n d easy . , ' t j;i :,q J./ 4t .? ' : 9 )jL ( qsjptojgt/ () b e j t 1 p u r h a e dtpyjyià u t/.:. ;: ljrwo. . ;u ) j ? ;) . .jj yjy j t z e ro ) t o b 1 I

. Se l - g t h b e r n g s - t h e p r - r'n e r V*;Lr j';;yy);L('.;'' ' ; ïjjqk 'Jt. ' %h;.Co 't (t.?.ft'tl /kp t..( a l'rl ()s . . . . .Ft; ég . t :J y? éjjrj :îj.) .k.):g? fq ;. ' $ p:' .)i 'Cétt 1 7 1p 7k j. 154; (E) 1L 4:j - :Et krk/ t-y ; 12 , 121 I -k :j l l-l t i t: e .l (:: L :, ( -8 ; ,1 1 I-1 ht )-1 I 15; .s y, tt j 'q ;:)' .;.):. .ï ; y... rs :..J pj . .j j j .

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k . ; ;. ( ty în t/xvu)4. .y): .# , ,.j : ya ,j ). .g::.t;k:y.ypyjj ;, nearjngs djscusslon sm aller easy to m a ke spi nd I e . A desig n Other special or unusual equipmen t needed.. '1 zt' ' ()J )* t'. i tkF it t ,frlptyë h s yj:l ; yë ; ?:.. '' EJ 7'q; i k ) i ' r p E ; ; ,fp 2.,sj ;) y t:yrf'p i'g t b'kt .) t; 171$2 t 2;r' f'Jyg trr2?ë ) q à:j r lt j ,., ; , ,,,y. 'î :.. .j .. ,) .?L?j'- .t , ) y, gy r .y,y ,k. ; - y,?.: ;.t:r; jtt .. j(yr . . . . . .22 t C j .3:)l33, T F ?''7l- 't ty t kt t. .j i j ; ; Ey . t, y,t jjvfjjtj lyyy jiy,,..t( yiy,î r .

.).j,? ?i $/$/ I 1L l-1 1r 1?k I:) t l r' , :j l:) ( , ësl r. I I-y fgj 15; j j,i 1 r-l (:: j I j (:j (E, (:l I r-l ht l-, I tsi I$$j (:j :E rs?j -I- jg . r-ù . (; j-y .r-l (;j ,. (sj 15j rr-j(5j y. .jiy) r.j 2(J2 12j'; jrj i 2 jr ltyki1t/Cq rJ)t rktg àk: ' ' 2t . kty.t , .. r s)?,. .. ,jh ,y j:g;;yyjj y,y j ,,..,jy j,y ; 3.j. ) : jjt ; jt :

t:tr q, . . . . .,%)t))t ' ytxéloj/ry: ykt: op..rkts: Lj k j yy y y yrjyyyryyjtjrtjyjj,tyyj vj-je selectlon of bearlngs Is not crltl caI book f or the more experienced turners . It 1/a inch (3mm) end mill 1 ' ')lnj y) j.s .llq 'v jy.. :.?j.: jjp L ;.x k. t j j :.j,y.j : gyj: jj ryj ) y j j , . .r/o llvfè: :t qlhsjj.( jtaz4ulyz, syrwsjlijztg/t ittjsl jiy; ( tk :jj j :; jyyjjj. yut should aIw ays be considered care- IS Instructive to lake a close look a't the11 . . .$p(?'t'l.y jj.nn , g .: yy. çtj, yjy ), ,t y::y)(. yysjyjyj j yy,y,gy::t j;.tjy y,jjv yjj jtyyjy,yyy,lô%.J?z??t, tr:y,y'itJ,ti. k ;,yëT,),:,t? yy sr, ,)yk$,y,jyk?y. tyyy, ,j ,,t,,.k,,)k ),y-,y,.yy) .y?Jytyy zj.yy r f uj jy .j n our case vve lnave two considera- draw ' ngs and see ho w the bearings and 'tLi 1t;F;p( )''. .g:t L?t , j: .j:r ,gt E j:k:r rt. j. : jt)k) kj y y.jr.yy y .

,y.k,,j$ ) yt ;j xj.gjyyj y .,.yyjy rryyyy yy jy ,,g)ky4j ,j,, yyj yyj .jyy. , roj .s , yyJ$' y ? h f. . . : qjt 9 : , . p ,y .. j:..rj rt ygj j jys jj j yys j, . .. .. .j .; ,; , ..y . g ,: r (,y ., .:.( . j .J . : J :. è: . .. . L . . /$ ; .. ... ;) ....E ;. .. .. ..; t . . , , . ' ' ' ' - ' ' h t w ill d'ctate Our selections . e Seals tend to push the spindle nose fur '

' ' ''' . ' ''' '.

' ', . . .

'.

$ '' ' ' ' ' '. , . tlons t aAllthe components ofthebasicspindle. The want to keep the cost Iow and we have ther out of the bearings (undesirable) .

'; ' ' ' o ' ''

emphasisis on designs thatuseas few compo- to be able to accom m odate a shaft that e w ill w ant to allow enough clear- .' '' , '

. ' .''

ble forease ofconstruction. w ill have a No 2 M T inside it. These tw o ance betw een the bearings and the ': , ''?,. ' ' b, . ' . ' #'' 'C;ents aspossl k .

j 4 1 5

7/23/2019 27 - Spindles


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Internal spindle assem blv of the basicspindle. Note the beanhg nut at the rear ofthe front twtl bearings. The pullev nut isused to hold the rear bearing tigh t.

Making the spindle

sequence of parts fabricationlt 1 s m u c h e a s e r t o b u 1 I d the s p 1 nd I e 1 f t h e

arts are m ade in the proper order - it iseasier to m ake the parts f t to oneanother.

W e w ill m ake the parts in the f ollowingo rd e r :

1 . Buying the bearings .2. The nut that clam ps the tw o front

bearings onto the spindle.3. The spindle itself (the part that

s p i n s ) .4. Cutting the threads.5 . The spindle housing . .

6 . Split collet f r holding the bearingcap .

7. The spindle front cap.

8 . The drive pulley.9. Cutting the keyway in the pulley.1 0 . M odif ying the pulley nut.1 1 . Cutting the keyslot in the spindle

shaft.1 2 . Preliminary assem bly.1 3. M achi ning the N o 2 MT in the nose .1 4. Cutting the spanner notches in the

cap and bearing nut.

16

1 5. Cutting the belt groove in the pulley.1 6. Final assem bly.

1 . Buying the bearingsSince everything depends on the bear-ings that w e will be using, buy the bear-ings first. This is critical because the fit ofthe bearings to the spindle com ponents iscritical. If we have the bearings at hand,w e can use them to check on the fits asw e m achine them . AII fits are to be m adeas stiff , push-fits. The stiffer the betterbut using force is not permitted. Both theinner race and the outer race of the frontbearings w ill be clam ped so the fit doesnot have to be as tight as you find on L j 1/8 inch slot 1/8 deepsome commercial products. The best fit - '; '.7 '' ')''t.

. 312w ill be one that can be seated and un- tt'$seated w ith light taps w ith a Iight plastic squre a .t Front bearings, oner race, clamping nut.m allet. Bew are that this seating and un-seating tends to Ioosen 'zonce firm '' fits.w e will not be using any adhesives (this * Cut recess. uearing seatis a personal recom mendation). * Cut threads.

Buy the nut for the pulley w hile you are * Chamfer aII edges and threads, n reads mustallowbearingstopass* Rem ove from chuck and set aside. .z'' overthem

out Iooking for the bearings. This is a%- 1 6 (see Appendix 2 for UK equivalent)nut preferably of unplated, unhardened Generally, if you have to cut a matchingsteel. internal and external thread, it is easier to

W hen testing tight fits it is important Set a good fit if you make the internalthreads first and then cut the external 1 shaq must be sma

vlloernjotugh tohat the bearings go in straight and that

ou have a w ay of getting them back out. threads to m atch. It is easier to machine allow nutto pass oThis is one of the conditions that dictates the Spindle to m atch the nut because you

can see what you are doing on the out- Figure 3.5 Thread/shaftrelationshlps.he part making sequence.side of a spindle as com pared to theinside of a nut as you try to fit the threads enough to allow the front bearinjs to. The nut that clam ps the front tw o

bearings onto the spindle One to the other. This being the case, the pass over the threads on the splndlefirst thing we need to m ake is the nut w ithout interference . (W e will be cuttingere is the machining sequence that wethat w ill clam p the inner race of the front the spindle threads Iater but we need toillfollow :two bearings to the spindle . plan ahead and think about their diam eter

The critical item s on this nut are that now . )Hold the blank in the 3-jaw . the threads and the face that w ill clam p The inside diam eter of the front bear-Face and cham fer exposed face

. to the inner races of the bearings . These ings is 1 .000 inch. W e will m ake the Reverse in chuck. tw o m ust be cut at one setting this will thread diam eter on our nut 0.020 inches Face to size and chamfer again .

* Drill through hole and open up to ORSLIKe that they are true to one another Iess than that.e also lnave to m ake sure that the

. 955 inch (adjust for metric bear- j.y 1 ooo - (0 . 0: o x 2) = o.:8o read diameter that we pick is small 'ngs).

OD 1.50 inches

Clearance recess0,975 diameter0.905 diameter

This side is thetrue side24 TPI

Recess is 1/8inches deep

17

7/23/2019 27 - Spindles


Let us settle on 0.976 inches because the outside diam eter to 1 .500 inches or 7 .000 inches overall. Check on your spindlethis is an even full turn on the average 0.500 inches more than the ID of them icrom eter and thus easier to read. bearings. Cham fer the outside edge () a1z i n c.x c c.x c. 000 in .e have a choice of selecting either 0.030 inches - that m eans the face of24 tpi or 32 tpi for the threads but I rec- the cham fer is 0.030 inches w ide. W e 'omm end 24 tpi for the beginner as being specify it in that w ay because that is the Keyslightly easier to cut. The finer the dimension that w e can see on the partthreads are, the more critical even very being m achined.

. c.a75 in thru holesmall mistakes become. We want to Turn the nut around in the 3-jaw and ,2 Morse Taperchoose a m ultiple of 8 for our threads so face it again. Bore a 0.903 inch diam eterthat w e can drop the half nut at any Ioca- hole in the nut. Bore a recess 1 .002 'x c .875 inion (on most Iathes) w hen w e cut the inches in diameter and 0. 1 25 inches 0.750 by 16 tpi

threads. The pitch of a 24 tpi thread is deep in the ring. This recess jermits the Bearing ID by 24 tpi 1.250 in dia0.042 inches. : bearings to rest on un-machlned stock. Bearing ID ' .' ''

''' See assem bly drawings. Cham fer aII 1.125 by 12 tpi ? .;1 /24 = 0.042 ''nside and outside edges 0.030 inches. ' ' , ',.

W ith a 6o-degree thread f rm , these Thread the bored hole at 24 tpi . The to- Figure 3.7 Seçtion along the splhdle. ' ' , ,.threads have a depth of 0.036 inches. taI Iength of the thread flank is 0.04 1 . ' ., - ' . ' '

inches (the sam e as the pitch on 6O-0.042 x Cos(3O) jjow . Hold the spindle blank accurately inegree threads) so you w ill have to make money on the easy parts no matter(this will be slightly deeper for 27.5 de- 8 passes at 0.005 inches each and then much fun it was (not unlike building the the 4-jaw chuck.greesl clean it up until the threads are right. Iocomotive cylinders first). * Machine the exposed end carefully.

Clean up the crowns of the threads w ith . * Put a large cenlre on the m achined. 042 x 0.866 = 0.036

. . l .1 som e em ery paper to get aII the burrs off Nose notes end.

and then som e. Take a very slight finish- First get a piece of paper and m ake a note @ Drill a W inch hole as far as you can. 036 x 2 = 0.072 i ng cut on the face of the nut. This is the of exactly how the collet closer fits on into the spindle.(multiply by 2 to correct for diameter) face that must be used to clamp to the the nose of your particular lathe so that * Increase hole diameter to F8 inch

This means that the internal diameter bearings and we need it to be true. The you can dupllcate that fit on the spindle (Iater to %).of our threads has to be 0.072 inches other face is not guaranteed to be true to Y0u are about to m ake. The most impor- * Next w ork between the chuck and aIess than the outside diam eter which is to the threads. tant part is to know how far the closer tailstock centre.be o.97s inches. cham fer the Iast thread on each side, Seats on the threads w hen closing on a * M achine the outside of the spindle

The threads should always be cham fered No 2 M T collet. It is critical that the closer nose form completely . Check w ith a,a7s - 0.072 = o.aoa inches internal does not bottom out before the collet has chuck and the collet closer. Thisith the thread-cutting tool.i

ameter (theoretical) cjbsed firm ly on the part being held. It m ust be perfect at this point.em ove from chuck and set aside. w e

place the blank for the nut in the 3-jaw will cut the two /8 inch slots, on the Would be appropriate to try more than * Mount a large face plate on Iathe.and face it on one side in the a-jaw . Turn perimeter, for the spanner wrench, Iater. One collet although the ones for b inch * Bolt another face plate to it, face to

and yi inch rods are the m ost im portant face..

a The spindle itself (the part that spins) lt is worth noting that aII collets are not @ clean and oiI the spindle nose justNext we w ill m ake the spindle shaft the sam e and neither are al1 tapers . Here l m ade. EsAurAxoues do not m ean the actual taper angle on the * Screw new spindle into second facetself This is the m ost critical part of the E i

parts but rather the other relative dimen- plate , aII the w ay. . . . xdxrees device and so should be made as early inE i E wsdegrees the process as possible .

I am from the Sions. This is because different manufac * Set it to run absolutely true. Abso-' ' ' ' turers follow slightly different standards Iutely true no matter how Iong it: : : : dow nhill school - get the hard part done . ,

first and then it's dow nhill from there on. takesere is the m achining sequence w e w ill * Tighten the two face plates one toigure 3 . 6 55 and 60 degree threads. The If you cannot get the hard part done, yobl

' 'II not have w asted a Iot of time and follow : tjae other.op of the triangle /à the thread pltch. w l

I , '

I 8 ' 1 9

7/23/2019 27 - Spindles


@ Using very sm all cuts, w ith a sharp there is nothing m ore accurate than w ork uacsneto 1 z4c- uia thou at this dimension.tool, face the end. done carefully between centres in a lathe j zsowqtomatch Rough turn 0.950 inches of the spindle zsg-dia raystock juck pla e to 1 300 inches in diameter. This is the Put a small and then Iarge centre on with a properly aligned headstock anclp.4 jaw chuc G .

In ,,the far end. tailstock. In our case w e are using the 1.125 Xlztpi section W e W ill form the M yford nose. Drill a r/'a inch hole to m eet the hole second face plate as one fixing but the register and threads onto. Now finish

on the other side. effect is the same. W e can rem ove anu nsotpsole - - - - - - - - - yailstock turning this to 1 .250 inches in diam eter. clean up the centre on this side replace the spindle with ease w ithout Ios- - - -Y=-- - and 1 ooo inch long. M achine the first. w ork betw een the face plate and the ing accuracy. AII accurate Iathe w ork is 0.500 inches of this to 1 .125 inches in

tailstock centre. done between centres. The 3-jaw chuck diameter. Machine a recess 0.090 inches* M achinelhe res' of 1he spindle body. can never be trusted to w ork w ith abso- w ide 'to cleer the threading tool. This

. cut the threads for the front bear- Iute accuracy . Any part that has to be 0.410. recess starts 0.410 inches from the end,,'''''

of the nose. It is to be cut in the threadednas clam n nut removed from the Iathe to be checked for Arbitcaryclearance oow,* Cut m ounting for the front bearings. any reason, m ust be made betw een cen- c aj2.. asx'' half inch and not in the un-threaded reg-@ Cut m ounting for the rear bearing. tres. Any part that m ight have to be ister part of the nose.. cut threads for the pulley nut. m odified at som e Iater date must be sexue. a . 8 work retw pe, at the nose o/' the

'r '- - 4. cutting the threads M ake a spacer to take place of pul- m ade between centres . Any part that has sntndleIey. to have another part mounted exactly to '- Twelve threads per inch is a pretty

into the coarse thread . It is easier to cut a thread Test mount front and rear bearings it for later m achining m ust be m ade 0 . 500 inch hole 3.000 inchesand clamp onto spindle with nut. between centres. The 4-jaw is a very blank. This hole has to meet the 0.375 this deep in two sets of passes - this

* Keyway is to be cut Iater . helpful device and does w onderful things inch hole that w ill be drilled from the reduces the Iength of the flank that the* Rem ove spindle. but does not replace doing w ork between other side. This side w ill be opened up to tool has to cut in half . Cut the threads at

centres. These are basic Iathe facts that a No 2 M T in the future. If the drilling the Iowest speed at w hich your Iathe w illW e have 'to m ake 'the spindle first are to be accepted as gospel by anv m ars the centre, remake the centre by run, in back gear. W e are cutting only 6

because we w ill need to have a way to aspiring turner. turning it. threads so it goes quite fast. Com pen-get the bearings out of the housing w hen M ake sure that the tailstock centre on Place a ball bearing centre in the sate for the Iarge threads by taking onlyw e make the housing. The spindle will be your Iathe is aligned correctly. The accu- tailstock and m ove the centre up to the sm all cuts and by using a very sharp tool.our arbor and handle, It w ill also serve to racy of the w ork done depends on this. part being m achined. There is a section in Chapter 1 6 on cut-guide the bearings accurately (when sup- There is a section in Chapter 16 that dis- Try to avoid using a pair of calipers. ting Iarge threads in two or more sets ofported by the tailstock) w hen w e test the cusses this and you will find this helpful if Measure the diam eter of the register on passes.fit of the bearings in the housing. you have never done this before. Your Iathe w ith your 1 -2 inch m icrom - Clean aII the threads on a chuck or face

The most critical part of the entire spin- eter. w e w ill m ake the diam eter on our plate thoroughly and use this as a gaugedle assem bly is the part that spins. lt has Note . nose register m atch this wlth this sam e to test the 'threads that you have cut. lt isto be true to the axis of rotation in every lf you are tem pted to hold the nose regis- m icrom eter. This will m ake sure that both im portant to realise that even the threadsway. If we get this right, we will have a ter in your 4-jaw, do not do it. lt will mar fefisters turn out to be the same diameter cut by the factory will not alI be exactlygood chance of having made an accurate the register and you may need to rem ove even if our micrometer is off by a few identicaland you will find that the nosespindle . Getting this right is pretty much the spindle from the Iathe many times to

a matter of building it in the right way. check it. This is not a 4-jaw chuck appli- ' l '' ' .The most important thing is to turn aII cation and cannot be done properly withoutside surfaces between the face plate a 4-jaw chuck.and the centre and to turn the internal Start w ith a 1 .760 inch diam eter bY - --- --

------------- -------------- - - ------- --orse taper in the actual bearings, i.e. in 6.376 inch Iong piece of free m achining .

situ. steel. Place the spindle blank in the 4-jaw:', ,.. - -,. . ..,;.' j. : . ., ,.?,; r,r .k . , . .?, . chuck and adjust it to run the outer en

Note true. Taking Iight cuts, face the outsideo matter what anyone lells you and face Cenlre drill 1he face w ilh a largeunder w hat circum stances, in your shop centre drill. Drill a 0.250 inch and then a Figure 3.9 w ork done at this stage.

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7/23/2019 27 - Spindles


that you have machined is tighter on and checkit out. lf yourlathe spindleis nol and we just drilled a centre at the other These threads are to match the threads' som e of your chucks and plates than it is running truly, it m ust be fixed before we nd that is at the centre point. Things on the nut we made. Their crow n diam -

eon others. This is normal. Try aIl the can proceed. Replace the necessary com - should be right. eter is to be just a few thou (0.025) Iesschucks and plates that you have in your ponents since repairing them is quite place a ball bearing centre in the than the ID of the front bearings. See Fig-shop. beyond our skills. Turning the plate to run tailstock again and m ove the tailstock ure 3,5,

Adjust the threads and the register to true is a solution butthis plate cannotthen centre up to the part being machined. In There are to be no threads under theet the fit vou want. You should have a be used on any other Iathe. Do not do it. this set up, the spindle face and nose bearings. The clearance recess for the

. ' bsolutely true as threading tool is to be right where thelrm fit that can be pulled up onto the reg - W e need two face plates for the nexl should be running aister with the threads without difficulty. step. You can use the 7.000 inch plate should the tailstock end. W e are now bearings end. W e need one full thread ofIt is very im portant that there is no play and the dog driving plate that cam e w ith ready to m achine the rest of the spindle. unused threaded Iength and at Ieastof the chuck back plate on the register. the lathe. If you do not have two plates If you are using a solid centre instead 0.375 inches of threads forthe nutto rest

M achine a 0.030 inch cham fer on the you need to make arrangem ents to bor- of a ball bearing centre in the tailstock, on. So machine 0.500 inches of threads.flange and register. Chamfer the threads row a plate or two from a friend. M ake you w ill have to w ork m ore carefully and Cham fer both sides w ith the threadingwith the thread-cutting tool. sure that the threads on your Iathe nose at Iow er speeds to m ake sure you do not tool, and cut 24 tpi on this section of the

lf you m ake a m istake while m aking and the threads on both plates are abso- overheat, expand, and score the centre. shaft. Keep testing w ith the nut as youthe first nose on your spindle, aII is not Iutely clean. M ake sure that both the Pay attention and keep the centre oiled cut the threads. If you over-cut, you willIost. Abandon work on this side, turn the plates run absolutely true. Check them. and adjusted. Even a ball bearing centre have to start over again, so be careful.part around and make the nose on the Do not take anyone's w ord for it. w ill get tight so keep an eye on it. There Put the nut on the threads and m akeother side. The bad side will aII be M ount the Iarger plate to the Iathe and is a lot of m aterial to rem ove. sure that it runs aII the w ay past the Iastmachined aw ay and no-one w ill be any Iightly bolt the sm aller plate to the First rough m achine the body of the thread w ithout binding. This nut has tothe w iser. m ounted plate as show n in the figure. spindle. Rough m achining m eans Ieaving hold the inner races of the bearing tight.

w e are going to m ake the reasonable Screw the spindle that you are w orking about 0.050 inches on aII shoulders and Now that w e can bring the bearings upassum ption that the Iathe spindle is true on into the second plate. M ake absolutely 0.100 inches on diam eters for finishing to their seating Iocation, w e can finishand that the face plates run absolutely sure that the spindle that you have just cuts. This is enough for two or three fin- machining the seat. W ork carefullv totrue. If there is a question in your m ind m achined runs absolutely true in the face ishing cuts in the hom e shop. m ake sure that the surface does no ' aetabout this, mount a face plate on the plate. M ake sure your spindle is fully The flange on the spindle will have a turned too far. M ake sure that the ce Wtrecleaned spindle nose and plate threads seated and tight in the second face plate. finished thickness of 0.375 inches. The is supporting the w ork properly .

Beginners should notethat a lathespindle nose side of this flange has already been Place the bearings on the shaft andtends to ride up on a thin oiI film w hen finished. tighten the nut down on them to checkrotated. This affects the centring of the First m achine the threads and then the the fits . Rem ove the nut and bearings

7'' F' Face plate p.nd. mounted part The test should be m ade seating for tlae double bearings at the and set them aside ./ 00 on a spindle that is being motor driven at front of the spindle. Here we want a tight we are now readyto machine the seat-y. 5'' or 7''Face plate ' tjle slow est Speed YOUr Iathe W ill permit Ptlsh-f t f or the bearings Leave this ing f r the back bearing . This bearing has.,'- hgted to other djm ension a Iittle bit oversize f or now. an I D of O.7 50 inches . The shoulderustec face plate . .. I .

' ':.,. under power. W hen you Stop the Iathe,tiae spindle will tend to sink tow ards tiae M akethe calculations and allow forthe formed will hold the inner race of the

' Iength of the tw o bearings and the bearing after the pulley and pulley nut, centre of the earth (0.0005 inches to1 5 inches). 'threads. Turn the rest of the shaft down have been installed on the shaft .vqs - - - - - - - - - - - - - - Tmusyocx 0.00

slx soE Takinc Iiaht cuts with a sharp tool,

10 Zhe root diam eter of the nut threads Assum e that the housing is 4. 250. .' m inus o.oos inches so that the nut can inches Iong as specified

. W e w ant the dis-ace the outside face. W e are not tryingbe brought up to the threads without tance from the frontofthefrontbeaçbog toto get the blank to the right Iength at this

.ajasten pirdlemounted #j c t d jjj itjj a o soo interference . w e want this diameter as the back of the back bearing to be 0 . 1 87xs point must 'n ' face plate ;;m ea;;-je nrkriejj - a

r ay-wjo. y-jj yoke. y . meet tlaa large as possible so that we will have a inches less than the Iength of the housingunabsyutelytrue u.w u.,.'. -, ,,, - - - ood shoulder for the back bearing to be or 4 .063 inches. Therefore the Iocationole from the other side. Clean up the @.

. tlghtened up against . Use the nut you of the shoulder w ill depend on the thick-igure 3 . 10 Splndle m ounted to face plates. Centre after drilling to create a true sur-. made earlier as your gauge . ness of the back bearing selected.ote that b0th ends of the splndle are dead face for the tailstock centre. At this point Next machine the threads for the nut. Turn the spindle down to the internaln centre. . . , , k . , you have tbe spindle nose running true

22 23, . . ' t , .

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7/23/2019 27 - Spindles


' ' ?'':' ing in the chuck jaws. If you have a and forth between these two procedures. 500 in . . -. bous

. :, 0.562 in , fixed steady it can be a trem endous until the part is running true. Tighten the4 2so inches ., , IargeL' ' ' I in supporting the outboard end of the chuck jaws a Iittle at a time as you go

; jae po.12s in -' ',' using. (but nOt too much or you will ruin the. ho The front bearings are Iarger than the chuck). It m ight be necessary to run a

. ,. , , .. . ' bearing so we make the back bear- smooth file lightly over the body and z4vp, . , back. . ,,. ing recess first. In this w ay if we m ake a polish it to get the bum ps and scratches

, . .. ; 1.s0 inthru hole :'.'..' ke w e can open the recess out to out of the w ay of your dial indicatorista

,j , . - - - - '.'' '' he recess for the front bearings. before you can get really serious aboutï bet

. ;:' f : The back bearing is designed to m ove centring the body.. Recess for .

. . . , . two brgs. ' ' Cb f back and forth in the housing as the spin- During these operations there is a large, . . .., . . ' ' ' d1e heats and cools (not much heating overhang outside the chuck jaws. Under

. Recessfor ; ' ' and cooling is anticipated). As such the these conditions it is very im portant to. . . . . 1 brg qlus , . 2 2so inch Recess for nut ' ;S ''.J''' '' bearing iS Clamped Onto the spindle and is take small cuts and work w ith sharp. , o jw Inches '

. t.'

, k' ' f '' '. free to move in the housing. How ever the tools. Using free machining m aterials ; p . .' . . : cs . ,. Figure 3. 1 1 oplndle 'IIINS/WJ. ' , ' . j.. jn tjje jjo using should be a f irm also heI ps trem end ously . lt is a good idea,:, .: : : 'ï ë m ovem ent

ush-fit with no jlay. This is the easy to re-check for concentric rotation beforediameter of the back bearing aI1 the way gested, the spindle will most Iikely be OK. way to make a splndle and would not be you make the final cuts.o the shousder Here again we w ant a Since it is not possible to turn the hous- suitable for an industrial spindle but we Face the housing and put in a Iarge cen-firm push-fit. ing between centres, a Iittle m ore skill and can get aw ay w ith this for the kind of tre in preparation for drilling and boring.

Turn the rest of the shaft dow n to care w ill need to be exercised. The im por. uses we are going to put our spindle to. First drill a hole 0.250 inches as far as0.750 inches for the pulley. The pulley is tant thing is to hold the housing as accu- The sequence of operations for making you can go. Open this hole out to 0.500to be a sliding fit on the shaft so you can rately as possible (within 0.001 inches the back bearing recess is as follow s: lnches. Bore this hole out to 1 .500 inchesget it off easily. Cut 0.750 x 1 6 tpi total indicated runout (TlR) along its in diameter and 2.250 inches deep orthreads (or match the nut you purchased) Iength and at any point on the diameterl * Hold the spindle body accurately in halfway (it can be plus or minus 0.050on the last half inch of the shaft. Check and keep it that way during the entire pro- the 4-jaw chuck for the entire length inches). This is a clearance dimension.that your nut fits this to your satisfaction. cedure for any one side of the housing. It of the housing. W e w ill m achine the sm all bearing end

W e are now done with the machining takes a chuck with straight jaws to do * Face outer end. .. . first. If we m ake a m istake and overboreof the outside of the spindle except for this. If you use sharp tools and take Iight * Centre drill. this end, w e can open this out for thethe keyw ay for the pulley key. cuts, you should not m ove the spindle @ Drill 72 inch hole 2% inches deep or Iarger front bearing end.

deeper. W e have to bore a recess for the back' * Bore out to 1 7z inch hole, 2 W inches bearing that is a firm push-fit for the back. The spindle housing ' .'

Now that the spindle can be used as a deep. bearing. The recess has to be 0.250handle for the bearings, we can start on : . . ;' . * Bore rough outline for rear bearing. inches deeper than the thickness of thethe housing for the spindle. * Finish bore for rear bearing seating. bearing. The bearing sits 0.063 inches

* cham fer a1l edges . inside the recess and there is anotherhe raw m aterial for the spindle hous-ing is a piece of free machining steel 2x o aemove body from cuuck. 0.187 inciaes on the otherside fortravel

inches in diameter and <.'s inches long. u ount tlae bearing on tlae spindle beforevlais allow s pisof an inch on each side for w ithtlae above inm ind uold tiaespindle you put itintiae reeess sotuatyou have aIean up and finishing. ) in the 4-jaw cuuck and get it running handle to pull it out with. Guide it in with YhO NOUSiRO Zfld tile S/irldle itsolf are ' ' ' . tFtle. Centre the part at the chuck end the tailstock centre so that it goes

f tho YOViCO . 11 is f irst and then use a S0f t mallet to move straight into the recess . Bore the recessho m OSt CFiticzl Parts Ojjaj that W6 gOt thOSO W ofkino ' ' .1''C,'/'''< 1, ' ' l i .7:I . the Outer end to the centre Of the sp i nd I e

. and check with the beari ng as you g o .SS C Rogether as perf ectly as we can . If you Slowly, gently - many small blows make Tighter is better than Iooser but not tooW orked betW oon the f aCe plate and the Figure 3. 1 2 Centre b0th ends of the splhdle Lll; One big bIo w Then re-check the part tig ht . There are n o threads on the hous-Celxre arld f OIIOWed the Seqklences StI9- housing. R6Xt to the ch uc k and adjust it . G o back i ng on this s id e . Chamf er al I edges .

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7/23/2019 27 - Spindles


Iies. W e W ill m ake the m ale threads to fit the bearings, clean up and polish alIsur. d about 0 . 375 inches thick (or Iong). taking place. The threading tool.. . , r ,.x n. z I I = = .n ... ,. = 8f1these so the exact dlam eter OT tnese Taces. Lnam ler aII OIJgOS anu klll=uus. will clean Up nicely to form a collet clearance recess gives us clearance histhreads iS nOt as critical as getting good Rem em ber that the threads are always 25c to 0 . 31 2 inches thick. past the threads.)

. ,, ,thread form. chamfered with the threading tool. Mako jjold the work in the 3-jaw with the . .Once the threads have been cut in the sure that the bearings are actually seat- s reversed. Bore out the collet so that The follow ing notes are applicable to aW

housing it is tim e to bore the recess for ing aII the w ay into the recess. This can j ae internal diam eter is about 0.250 aII thread cutting but especially so to thethe nut that holds the tw o front bearings. be confirm ed by taking accurate m eas. jaes Iess than the outside diameter of finer threads: w hen cutting the finer nccheck dim ensions from the nut at hand urem ents from the front face of the hous. jae part to be held. In our case this will be threads, the profile of the thread-cuttingand proceed accordingly. ing with a depth jauge. g inches. This is not a critical dimension. tool becomes critical because any imper-

Now the critical part. The bearings are Take the houslng out of 1he chuck. fections in the profile w ill lead to im per-each 0.600 inches thick so they will take Now you can put the back bearing in the Notes: , . ' ' fect threads and on small threads w e doup 1 .000 inch. Added to this we need back recess and put the spindle and bear. not have a Iot to play w ith . It is also0.1 25 inches for the threads for the cap ings into the housing from the front. It (a) w e need a 0.1 25 inch or longer reg- essential that the tool be mounted toso that the total depth of the recess for should run sm oothly and w ithout binding ister to hold the collet adequately in m eet the work at the right angle . Honingthe bearings is 1 .1 25 inches from the or friction if you have done your w ork the chuck. W e need a recess of the thread-cutting tool on alI cutting sur-face of the housing. The outside diameter right. ' about 0.1 25 inches to hold the part faces is recom m ended. A sharp tool w ill'' . . '

of the bearings is 2.000 inches. W e need in the collet. Unfortunately 0. 1 25 form cleaner threads, a dull tool w ill tendthe bearings to be a push-fit in the recess. 6. Split collet for holding the bearing cap and 0 . 1 25 m akes 0.250 so if we are to tear the work. This can be seen quite

W hen boring to a fixed depth, it is best Hom e-made split collets are a good way not careful, the register and recess clearly under a 1 O power m agnifierif you can set up a stop for the carriage. to hold thin parts in a 3-jaw chuck firmly will run into one another and we will Examine the w ork after the first cut toA m icrom eter stop is the ideal, but an and accurately. In general split collets not be able to hold anything W e m ake sure that the tool is cutting clean .

ordinary stop w ill do at a pinch.Having a need to be m ade of m aterial that is 0.25C have to keep this in m ind w hen m ak- W e need to clam p at Ieast ?/a2 inch ofives you one Iess thing to worry inches in diam eter larger than the part ing the split collet and w e have to the rim of the bearings. AlI shoulders thattop g

about w hen you are doing a close toler- that you are trying to hold. Since w e are Ieave a Iittle m aterial here and there meet the bearings should be at Ieast that

ance job. going to hold a 2.250 inch part, we need to hold everything together. It is high. If more material can be provided,Once you are satisfied with the fit of a blank about 2.500 inches in diam eter easiest to m ake it so that the register the contact area or shoulder should bediam eter is Iarger than the recess m ade the sam e size as the race of the

Markjaw#l and identify . ; ,.,y diameter. see Figure 3.1 7. bearing. This applies to both inner and, osnovksiorinr, workowith. ', ' (b1 Be sure to mark the location of chuck outer races. Needless to say, in no case --- --'- ' = - - jaw num ber one on the collet before should the clam ping surfaces touch thesco .

. . . . . . . ' you remove it from the chuck. Also seals on the bearinas. On m ost bearinas* -* . 2 3 00 ;... - -. -.

. mark the identification num ber of the inner race rotates in the seal and the. ( . ' j -.. .... cut between 2 .

2so ' the Chuck on the collet. The split in outer race is fixed to the seal On m ost.. . . , . jaws the collet should be between tw o sealed bearings the seals w ill be below

I *,

; . 1 a.oco jaws and not at a jaw. This collet is the bearing races but we must make sure' l ' : good onl for holding this one diam- that they actually are.

j eter in thls one chuck.:.' : ,. . , ,.,.

,

, . (-) w- n--d at lea-t t'---e t,----d- to , . vhespi-dl-f---t-ap'. I .

. ' assure ourselves that w e will get Now that w e have a w ay of holding the. ix ç . ' '' . -

.1 . . ' ' proper engagement. Theoretically, spindle cap, w e can m achine it.

' . . . . . .-' One thread could be sufficient but we You w ill need one piece of 2 W inch

' need tw o to m ake sure that we get diam eter free m achining steel 0 . 375 +' I 0.187 inch 0. 125 inch Contact aIl the way around and w e inches Iong f or the f ont cap f or the . .

need the third thread because w e housing. This is the sam e m aterialthatFigure 3.17 W ith the exception of the 2.250 inch holding dimension, the dimensions m ay Ieave one thread un-threaded to the spindle housing and the pulley areof the split collet are not critical. gtlarantee that clam ping is actually m ade of .

28 '' 29

7/23/2019 27 - Spindles


j , I . , .t. I.ut the m ateria in the split coliel and 1he tool nose slightly. The pum ose o u .a0 : w =--- --- . ' . ; h .. , . ':' ''- face it. If the blank you got is not cut round nose is to give you a finer finish ,

''** '''''''' V'**'''''%'*' 1, ('?. ' ' '' .'

'

. ' , ; .

areading tool 'quare to the axis of the rod or if there is Generally, the larger the tool nose the 24.rp1 . ' '.clearancea rough saw cut, take these into account sm oother the finish (w ithin Iim its of ' ,

'

w hen clam ping the part so that it w ill coursel . 2 2so inch diameter . 'face true. Clean up the face. Put a slight W hen cutting anything over 20 . . . . ..

chamfer on the outside edge, about threads per inch, be particularly caref ul sousiog ' 'N o3o inches wide to m ake sure that the thread crow ns do

Turn the qart over and turn down the not interfere with the base of the thread oo jnc: diameter isthe ''1 oortion that Is going to be threaded to the on the nut. If you start getting a point at outsiuediameterof theright diam eter. The diam eter should be the thread crow ns w hen cutting the ' bearings :o 08O inches greater than the inside threads, file them down imm ediately ordiameter of the part that is going to fit you are Iiable to get an erroneous fit. Threading tool ' ,

Glearancee . . .'. ' ' 'hese threads , in this case the body of (This condition m akes the nut seem f,.

the spindle housing. The bore of the spin- tighter than it really is.) Bearing Nut colsz inr. ' ''

dle housing for the bearings w as 2.000 Once the fit gets close: take two -'' .. 'we made the inside diameter of passes at each setting and cut only 0 001 s

gure a.1: secgon across t:e bearing nut (cap) penw eter. ).,inches.the threads 0.01 O inches greater than inches on each setting. File the crow ns of

inches so that we would the threads down as they are created . Try . 'this or 2.010not disturb the bearing seat. Threads at the nut after every pass. Check the the bearings there in place there should Notes .

.

24 tpi have a double depth of 0.084 thread crow ns after each pass. Now is be a 0 . 032 inch gap.nches so we have to start at a diameter not the time to make a mess Bore the hole in the cap out to 1 375 (a) The ring clamp is threaded into theslightly over 2.1 00 inches and w ork The threads that this cap has to fit have inches in diameter before rem oving from housing to hold the bearing outerdown from there. Cut a recess at the already been cut in the housing for the the collet This hole should be bored at race because this form of bearing

iII recall that these were to the threading setting to be comjletely clamp allows us to have the smallesthoulder to clear the thread-cutting tool spindle. You wat the end of the cut. This should be have an inside diam eter of 2.01 O inches 'true to the thread axis . W e are sooklng for possible oulside diam eter f or 1heabout 0.030 inches w ide and 0.040 but it is w orthw hile checking this again a hole that is 0 .004 inches Iarger than housing. In this case the housing w illinches deep (radius). before starting. the spindle flange i e. 0.002 inches clear be 0.250 inches larger than the Iarg-

M ake sure that the blank actually seats W e need a register that is 2.100 inches all the w ay around . est bearing (in diameter). This givesfirm ly in the split collet. Take light cuts in diam eter and O.1 57 inches Iong for the Now place the bearings on the spindle 0 . 1 25 inch of w all on either side. Ifwith a sharp tool when working with a threaded portion of the cap. On this we and put the w orks in the body . Tighten we wanted to bolt the bearing clamplarge piece in a split collet. Use a hone to will cut O.1 25 inches of threads and the cap onto the body and check the on, we would need at least 5/ s inchget the best edge that you can and round allow 0.032 inches for the recess on the clearance betw een the cap and the body . on each side and m aybe m ore. Bolt-

. ; , , inboard side to clear the threading tool, It should be betw een 0 . 030 and 0.035 ing down is also m ore w ork.we can cut 3 threads at 24 tqi on a regis- inches. If it is not, you can adjust it by (b) When a milling cutter cuts , it pulls

ter 0. 1 25 inches long. W e wlll cut these m achining the cap at the appropriate the sw arf out of the cut. This in turn'

2.250 inch diameter threads by turning the spindle by hand, Iocation . pulls the cutter into the cut. This pull

Chamfer a1I edges and threads and set has to be taken up by the front bearfter each pass check the fit of the.c90 inczt diameter tjae ca p aside w e w ill cut the 6 ings and these are held in w ith thehreads with the body of the spindle. .2.010 inch diameter stop cutting and clean up your work a5 Castellations for the spanner wrench in it cap w e are machining. So it is im por-2 ()4)0 inch diameter soon as the threads start to engage, later on after w e set up to do aII this and tant th at these threads f it w ell and

5m 00th down the crow ns and cut the Similar work at one time, in the Iathe. seat as perfectly as possible. Full '

: , threads 0.00 1 inches at a tim e until yotl threads that engage f ully are needed.

get the threads just right. W ithout thegigure a .1 a Approximate dimensions of bearings in the housing, the cap shoul , . . . . ..

what the nut has to m atch. . . thread aII the w ay into the housing. W ith .. . .. : ,c , b ,. ;; ::,. . , '. )r. . , y :, :

30 1 ' ' ' ' 31.

, ' ' .

7/23/2019 27 - Spindles


a vsedrive pulley dIe. yse a.cso incu puIjey sbown is ti,sNow is the time to decide wuat kind of standard pulley for this spindle and ispulleys you are going to use to drive this suitable for most m illing applications. lt

k the back of the spindle to can be replaced w ith ease so you canpindle . M a esuit your particular needs. The descrip- change your mind Iater if you Iike. Notetion covers the standard for pulleys with that even keyed pulleys have to bea 0.750 inch hole and an O.1 25 inch nutted dow n because the back bearingsquare key (as found in most hardw are on this spindle (which bears no axialstores in the USA). Ioad) is held with this nut. Do not use the

The pulley should be cut to m atch the set screw in these pulleys.belt that you are going to use. The draw - First m ount the blank accurately, cen.

ings show a pulley that will work with tred in a 4-jaw chuck. Lightly face thebelts that are W inch to Xz inch at the wid- part and chamfer.est part of the belt. The narrower belt is ''Mount parts accurately in the 4-jaweasier to use and is m ore than adequate and centre them '' m eans that the totalfor everything you w ill want to do w ith a out of round from side to side on the dialspindle Iike this. It is also more flexible. indicator is Iess than 0.001 inches notBuy your belt first and then work to it. counting the blips caused by scratchesThe belt top should be even with the out- and imperfections on the surface. The

ide of the pulley w hen it is seating right. part should be checked for ''on centre''The pulley is made from a piece of free on each end if it sticks out of the 4-jaw

m achining bar stock 2.250 inches in over 2.000 inches. The condition of the

diameter and 1 .000 inch Iong. This is chuck you are using has a lot of effect onade of the sam e stock as the housing alignment. W orn and abused chucks are

and cap. harder to use.The intent of the design is to allow any The 0.750 inch shaft for the pulley istandard run-of-the-mill pulley with a :4 intended to be long enough to allow you

inch bore and a key slot to drive this spin- to m ount standard pulleys on it. There

0 187'' 0.375.'

. ---1 l ,, 093

40 deg incl hangle 1.250''

'.. .'

. . ,. .' . ., t, l '

.; .. ' . ., : .

sgure a ao secpvn across rhep,,,epzrw /ep slwen i.ona.

32

be a need for som e modification of aaYmm ercial pulley to prevent interfer-oce with the back bearing and housing.n

select a pulley w ith a keyw ay rather thanneeding a flat for a set screw .ne

I have designed the pulley so that it isthe same diam eter as the spindle hous-ing, It is better to do it this w ay because aIarger pulley tends to get in the w ay m ostof the tim e and is not needed for thehigh-speed w ork this spindle w ill be usedfor m ost of the time.

The sequence of operations for m akingthe pulley is as follows:

First hold the pulley stock in a 4-jawchuck and m achine one face of the pul-Iey. Holding the stock deep in the chuckw ill ensure that the body of the m aterialis held accurately in the chuck so that itgets faced at right angles to the axis.

Drill a 0.500 inch hole in the pulley andbore this out to 0.740 inches and thenream to 0.750 inches. W e w ill cut thepulley groove between centres afterm ounting the pulley on the spindle. ltcannot be done at this tim e because w estill need the blank to drive the spindlewhen we machine the Morse taqer. Theforces required to do this are qulte Iargeand would ruin a finished pulley. M ore onthis later.

l have selected bearings w ith integral,double seals. W hen clam ping the innerand outer races of these bearings it is im -portant that the seals not be touched bythe clam ping faces. To ensure this youshould turn away about 0.010 inches onthe entire face of the pulley boss except

for the part that is going to clam p to theinner race. Take a close Iook at the bear-ing seals lo see w hat you need to do .

9. Cutting the keyw ay in the pulleyThe keyw ay in the pulley can be cut byusing the lathe as a shaper. The pulley isheld square in &he chuck and a key-shaped cutter is held dead on centreheight in a boring bar in the tool holderThe lathe chuck is held firm by som em ethod and the key cutter is movedacross the pulley bore manually by tra-

versing the carriage. It is possible 'to takecuts of about 0.005 inches with eachpass.

Depending on how carefully the cutterhas been made, it m ay be necessary tom ake a holder that w ill allow the finishedkeyw ay to be broached by a square toolof the right size. The holder is a 0.750inch shaft w hich has had half the keyw ay

@ De-burr 1he blank.. Hold the stock in the 4-jaw chuck

and centre with W inch sticking out.* Face 1he stock.@ Turn a boss :6 inch Iong and 1 .375

inches in diam eter on face.* Centre drill and drill ou1 tol/z inch.@ Bore out to 0.740 inches.* Ream or bore to 0.750 inches for a

Iight push-fit on 1he 0.750 inch spin-dIe shaft.* Hold in 4-jaw chuck by the register.* Check centring and axial alignm ent

with the back of the spindle in thebore and a centre suqporting thespindle head from the tallstock.

* Tighten dow n the chuck as you cen-tre the pulley,

* Rem ove spindle.* Face pulley to correct thickness .

* Cut keyway .

* The belt groove w ill be m achined

Iater after m ounting to the spindleShaf't to guarantee absolute concen-tricity.

l recomm end a 2.250 inch diam eter drive

pulley as this is tbe sam e size as the bodyOf the housing . lf you w ould Iike to fit aSmaller or a larger pulley

, that can beone.

. ,

33

7/23/2019 27 - Spindles


illed into it The other half of the gouge the surface against which they ne careful that you do not damage the can remove the taper and mount theeyway is in tlae pulley The tool is a work. A plain wasber may be made up if casteélation. spindle on the latbe as shown in Figurestandard o .

1 25 by o.1 25 inch turning you like. push the spindle in from the front. The 3.23.tool that is ground completely flat and installed back bearing will hold the spin- W e will drive the spindle with the :ul-

1 cuttinq the keyslo: in the spindle dIe at centre and make it easier to Iine Iey held in the 4-jaw and support theharp at the cutting face. It can be 1 .ressed throuqh with the tailstock for the shaft things up. nose end in a fixed steady. w e w ill do

F. lide and a small angle screw in the front cap and tighten it this after centring and aligning the worklnal pass. If you have a Iarger drill press Use your vertical sthis can also be done in the drill press. or vice to hold the spindle at the righ down good and tight but again be careful as perfectlv as w e nossihlu r-nn

careful filinu can also be used to finish height to cut the slot forthe key. It is also that yotl do nOt damage the castellation. Hold the 'ulleye Jd of '- '' WW'' Jdle in thethe keyway. - possible to clamp the shaft to the lathe Install the key on the back of the spin- 4-jaw chuck and support t 'e nose end

cross slide w ith the right am ount of pact dle and push the pulley onto the spindle. w ith a centre in the tailstock. Adiust the

10 uodifyinq the pulley nut ing under it to do this. Install the nut on the back of the spin- 4-jaw until the spindle is perfeclly cen-vou will need to purchase a :y4-1 6 (see cut the slot 0.063 inches deep with a dIe and tighten it. If aII is well we are now tred. Usino the tailstock koonq tla=e orx'lAppendix 2 for UK equivalent) unplated 0.1 25 inch diameter milling cutter. Two ready to machine the Morse taper in the aligned. Tilhten down snu -' -M '- t W''Q*V 'lll'nut and modify it. see the drawing for or three passes should be sufficient tc nose. We will machine the pulley groove - we will -e takina some h'avu--t YP *''/+1the modifications required. get the depth you need. The slot shoult Iater. Right now we need the pulley as it the reamer and wW need to ho'd-z o alZ ' '

unfortunately large, unplated, com- go almost to the shoulder for the bearing. is to hold it in the 4-jaw as our driver. W hile still in this nosition. nos-tooW'xohY'cially m ade nuts are not quaranteed It does not have to be cut across the Take it aII apart. fixed steady on th' spindl' '-t the nose

m erto have the threads either in the centre of threads and a short slot (0.500 inches) bearing to supoort it firmlv.the nut or particularly in Iine with the axis just under the pulley is OK. 13. Machining the No 2 MT in the nose The secuen 'e for doinz#lao wzxrle ;0 aof the nut. I w as surprised to discover Clean up your w ork with a sm ooth file. First we need to set up the com pound follow s: O * W''W

,

0 W' 'h

.

'* V'C'

othis (or l may have got my hands on a slide at the Morse taper angle. W e can , .articularly bad nut). This being the case, 12. preliminaq assembly use a No 2 MT plug to help us. See Figure @ Hold the spindle accurately in the 4-

.h ide of the nut should be re-faced A word of cautlon here - do not use any 3.22. It is preferable to have a ' steeper jaw chuck by the spindle pulley.eac s iul

e if than needed'' taper as opposed to a . put the tailstock centre in the centreafter it has been mounted on straight, adhesives, anyw here, if at all poss , zz shallow er than needed'' taper. in the nose.athe cut threads. I used a Y.-16 (see you ever w ant to take any part of thisindle apart. The design does not Iend Once the compound is adjusted we . centre accurately in the 4-jaw . 'ppendix 2 for UK equivalent) nut and sp

m achined it dow n to about 0.376 inch. itself to disassem bly if things are gluedThe inside of the nut is relieved to allow together. However, adhesives can bs ' . . . '

f the shaft to be available as seat- used on the inner races of the double Centerin Iathe .m ore o o a7s inch shaft withpindle. . .

.

ing for the pulley. Do not use a Iock bearings only and now here else. Do not accurate center held 'w asher under this nut as these tend to do it. . ' in drill chuck . ,

First, clean everything, especially all ' ' .. .. .. . ,. .

, threads and alI bearinj surfaces. Then .. ,..,... ,. .. () 12s,, deep ' Iightly oiI or grease (whlte Iithium ) every' . .. ., 1 thinc for rust Drevention and ease Of .

bl ''' assem Y..'-' ''

. Push the back bearing into its recess. It , ' . .' '-

b-

' 'h. - - - - - - - - - has to be able to move in this recess as j, - :. ' ' h indle warms up in use, so it siaould Dial indicatormountedoncompound ... . t e Sp . ,..

l . ' and moved back and forth with. - . y .-. ,

. -. not be glued under any conditions. Dû (j sjide to set angle of : ompounI not allow this bearing to f aII out as yot compound slideI Turn down to bjroceed With assem y. .

0.375'1 thick .. , . . . . .,. . - .m. put tne tW O îronl Dearlngs On Ine Spllr .9klFe 3.22 How to set up the taper angle on the compound slide . M ount the 7 r. h'' ' ' dIe and nut them down as tight as possi' di&l indicator /W compound and aëbst untll compound p:s para//e/ to the taper .

'

Figure 3.21 Modlficatlon of a commerclal DOJP. X steeper taper /s preferred . )

.y4- lsnut. t . . . ... ,., , .. 1;.. . ,à. . r ? ?. ) ? , bIe w ith the nut that holds them in place'

' >

..

7/23/2019 27 - Spindles


J , j jathe like my South Bend, the travel the reamer out if you have to-. s inc j g (joc jncjjes jt takes a M6 inch hole to start the

r tjae compound is on 9 .old accuretel y in 4 j aw on . (:ç On eed to bore about three deep ream er in the spindle and it is possible tothe unfinished pulley. and We ncenter with . jd take a m uch larger latbe to do go all tbe way to the finished taper fromo it w ouailstock center .j , . tjje job. Rough bore in sections, use the this hole with just the reamer (if you are

,, and tjaen scrape to fit if need be. using free machining steel) . However thiseamer

; vou should not have to scrape if you makes a Iot of work for the reamer and

. - -. - - -. - - - - - -. - - - - - - - -- nOt t

.. . . . . -. . -. . . . .. . .. . . .. . ..

'' m aking internal No 2 MTs so do not Since no-one l know has drills over

r money and time buying or 0.500 inches in diameter in his home spend youyorrowjng a taper attachment for this shop, we cannot step-drill the hole and, . . ). 2 project. will have to bore most of the hole for the

X Hold in fixed steady The taper reamers come in two forms, Morse taper (No 2). First bore in aboutr : , at front bearing,Hold j a roughing ream er and a f inishing ream er. 0.062 inches at 0.68 5 inch diam eter as a

. . ' ' . '

1 must be firm. jj the roughing reamer m arker. M ake the bore so that it is tight, i t ' t YO U CZ d O W it O tlt. :

, ., , , . . but you do need the finishing ream er. on a taper at the inside end and loose on

The roughing reamer Iooks just Iike the the outside and not the other way around. . . , jj jjnjshjng reamer except that it has som e - w e w ant the taper to be bored stee er, ,

. . . k , .. jFigure a.2a How to set up to rnac/wy?, the No J MT. ?, . tiny scallops cut into each of the cutters than it needs to be. w atching the outslde

.to break up tlae chips. end so that it does not get too Iarge is

If ou have a choice get a ream er w ith m ade easier by m aking the 0.685 inch set spindle to run absolutely true at accurate M orse taper hole is w ith a y ,he l-jaw . Morse taper reamer. lf you cannot afford a flat at the end of the Morse taper tang. section indicated above. W hen it gets

. M ount the fixed steady atthe double a ream er, borrow one or if that is not pos. This is very helpful if you manage to get close, start using the ream er. Use thebearinss and set. sible, have a local m aclaine slnop do the the reamer stuck in the spîndle for any of slow est back geared speed on the lathe.

. Rough bore tlae M orse taper hole w ork for you. The spindle can be held in a a num ber of reasons. If the ream er gets Be absolutely sure to put the Fa inch thru-

sc or Iarger collet to do the work fairly stuck, it will come loose in the tailstock hole in the spindle, as suggested above,ith the compound slide.. Finish ream the Morse taper hole and quickly. tnot good) and you will have to release it before you start. That hole will help you from tlae spindle. lf there is no flat on the knock a stuck ream er out of the taperadjust for depth. . ï These notes will be of assistance if you. Rem ove spindle. have never done anvthing Iike this before tang, and no hole in the spindle, you are As you proceed, check the depth of

co in trouble because there is now no way the reamed hole w ith the collet and thenow . M orse tapers are about o.sitical inches per foot or 1 in 24. The various to get a wrench on the ream er. Discard collet closer. It is im perative that this

'rhe depth of this Morse taper is crford Morse tapers (No 1 to No 6) are not aI1 at tbe spindle and discard the reamer and does not become too deep. The spindle isecause it has to be such that the M yiII close properly w hen the collet the sam e taper. The fit to the taper is Start over. alm ost done - now is not the tim e for in-collets w Tlae reamers are to be used forthe final attention to details .closer is screw ed dow n on the nose very sensitive to the angle of the taper,hreads .

Tlne best w ay to make sure that There is no realistic possibility tbat we sizin: of tlne taper only . The Iength of cut clean up, chamfer and qolish aIl sur- alonq tue re am er is so long tiaat it is very faces. Rem ove from chuck In preparationhis will indeed be the case is to have a m iqht harden, tem per and then grind this I taper. It is not in the cards to have equip. hard to hold the ream er in the tailstock for final assem bly .

collet closer and a half inch collet a onj wjjeo makin: these cuts. work carefully . , ..ith an accurately m ade (ground if possl- m ent fike that in the shops of hobbvistsand use Iots of cutting oiI w hen m aking 14 . cutting the spanner notches in thele, use an oId x inch end mill shank) half and amateurs. w ith a Iittle care, ac thes

e cuts. Take very Iight cuts and work cap and bearing nutnch rod in hand while the machining is unhardened taper will take us to the endt slowly to avoçd gettlng tlae cutter stuck Before we can get to final assembly, weeing undertaken

w e w ill need to have of our days. The best w ay to ensure a f in tjjq taper . jjere again l caution you not need to cut the 0.125 inch wide notchesabout half a turn Ieft to go on the collet is by trials and scraping after using t inthe collet. M orse taper ream er. lt is not possible to to start unless you laave tlae Iaole tlnrouqh in the nut forthe front bearings and in the

closer whentheshaftistig thespindje i n place so thatyou can knock front cap. w e will cut 2 notches in thehe easiest and only way to make an bore a taper because even on a s.ooû

36 37

' .'. ', d

7/23/2019 27 - Spindles


, we do way set the com pound to -20 degreea tj je most suitable for high-speed the shaft does not have to be theearing nut and 6 in the front cap. not actually need 6 but 6 look best. and cut the other side. Finish the bottom rk . same size aII the way between the1 25 inch diameter cutter held of the pulley groove. Make sure that both W0se a . . vjje back bearing has to be smaller two bearings and w e w ill not have toin a collet in the Iathe spindle to do the sides of the pulley are even. Cham fer an4 tjjan the front bearing to allow the m ake a close - fitting tube to spacecutting. If you have made the George polish up your work. ut to be jlaced on the front bear- and clamp the two bearings (asThom as dividing head, I do not need to .''? ' Ajso It is easier if both bearings w ould be needed in som e of the de- ings.tell you how to cut the notches. If you 16. Final assem bly not the sam e size because then signs presented Iat er on).reave not, you should consider making Clean a1l parts and oil Iightly. ,

this excellent tool. l will describe how to Assem ble as before but this tim e , . 'i idin head tighten everything down for good. . : ''' .' . ' .' '' ,7) : ' , ''' ' 'o it w itbout the d v g . .)., ;t . f , . : . ; ,.. ..d the nut and then the cap in the 3- Happy m achining is around the corner . t' ' 'o . , .

( jaw and mark out two and six equally The spindle will be ready for its first joL .) ..,. '., : . , .spaced m arks on them respectively. A as soon as we can m ount it. A sim ple but , .' , . .:. . ' , . ( . ,, : . : ,

tool mounted at centre height w ill allow versatile m ount for the vertical slide w ill , ' . ' . r. .., . .'

,'

, .'. . f ..

you to engrave a diameter accurately. be described in the next chapter. . . .. . . .i You can engrave three equally spaced di- ' .

, . ,

am eters by indexing on each of the 3 Notes and com m ents ' . : ,jaws of the 3-jaw chuck. This gives 6 . 1: , , ; . . , .equal divisions. * lf you want to take the big hexago- ., ,. . , ,

Nextsetupasmal, ang'e plateonyour nal nut off tkae back of t'ae sqindle . . . .' '''. .. .. ' .. : . .. .'. ( :''. ' .'vertical slide and place stops on the angle hold the front of the spindle In a 3- ' ' 'plate so that you can cut the O.1 25 inch jaw chuck with soft copper or alu- ' , , ;wide by 0.1 25 inch deep slots in the nut minium packings and use an (adjust-and cap. You should be able to cut 0.062 able crescent) w rench on the nut. , ,

inches at a tim e w ithout difficulty. The * M ake the key for the pulley of brass , 'cross slide and carriage are Iocked in for ease of filing. Brass is m ore than , . '''place and the cuts are taken by m oving strong enough to carry the Ioad , , '

the vertical slide up and dow n. W ork care- being transm itted. . , '' .fully so that you get a nice looking job. * The hole through the sqindle has to , , ) . .I

Deburr the parts. be at Ieast Ya inch In diameter . , ,. because the draw in bolts for som e . , ,

15. cuuing the belt groove in the pulley of the Morse No 2 milling holders use ,

First get the belt you w ill be using - a K this size to pull the taper in. Since , .. . ' ' ',nch wide belt is fine and a smaller belt this hole is drilled in a Y4 inch part of ., : , ,

'': ''? ' ' . . . . .w ill w ork too. The forces we intend to the shaft, this hole could be m ade li ' '

. . (ransm it with this belt are quite m odest . inch w ithout encountering any diffi- 2:. , : . , ' 'l ' ' 'A sm all section is m ore flexible and easier culties. This would allow Iarger parts . , . . . .

'. . . . . . .

' ' '.' '

.'

'

.. . ? . . .. . . , . . ;to handle. to be held through the spindle but . . , ' ' .' r )

Set the spindle w ith the pulley m ounted can also cause out of balance of .S , , ..'

on it up between centres on the Iathe. problem s at high speed if everything . .. ,

,'

,

The included angle in the pulley is 40 de- is not centred in the spindle properly, .'?

....,,;

. ' ' .' ) ''grees (orto suit your belt). First rough m a- Unless you have som e overwhelm- J I ,chine the groove w ith a parting tool. Next ing reasons, Ieave this at Ya inch at .

. , , : . . . j ) . ; .setthe com pound up at zodegrees to the this time. In any case you slaould .ross s lide or to suit your belt, and finish avoid draw bolts as bad practice and . ' , ,.

'' i.

' ''.''

. ..

'

cut one side of the belt groove aII the use the cotlet closer m ethod as being , .' '

,

', .

' '.'

38 l ., t 39 . . . .' . . ' ..I ' '. . . ,'' i ' ' '

.a n wa v m a x oo ndardclamshellm ount Cutthem aterialandthenfaceoneIong

7/23/2019 27 - Spindles


a n w a v m a x , , oo ndard clam shell m ount Cut the m aterial and then face one IongL M lA.r I Ln * . : . - -'- t we will address the clamping plates. side on each plate so that you have a true yirs.,, . . . . , . , . , . . , .. . vye sequence of operations is as follow s: surface to work from . File the burrs off

. , . , , . ,> y. . . . -. , 2 ' the m achined sides. File aIl edges to

. , , .,r,. , .. , . , ' . . . cut plates approxim ately to size remove aII burrs. In these operations it isJ i ' ' .. ' .' , ..... j . . . . .,, , , , . .,, ï, ,. with a saw . im portant that the m achined faces be at

,' '

., , . :, h . , . square and size plates in Iathe or in a right angles to the plate faces.' . milling macbine. Next m achine tbe side opposite the

x x , , . :jue and m ark up the plates. first side that you m achined. Again file

jj n t e S 1n 10 . Drill one of the W inch holes in the the burrs off . Check that you have platesun . f ce Of One Of the plates. that are exactly 2.500 inches w ide and. . . ,

'

@ use this hole as a guide to drill the 4 that the sides are parallel. This is impor-, ,. holes in the other plate. tant. coat w ith Iayout blue and m ark up

' . I tes together. the plates so you can see what you will. . clamp the two p aiI1 the other three holes in the first be doing in the next steps. or

Introduction . ' Parts needed plate. $ . ,. ,.. L ,: Machine the third side of each plate. j joles. yile the burrs off. M ake sure that each Deburr a

There are a number of ways that a basic 'rhe vertical slide mounting consists of . Bolt the two platec together. corner is exactly 9o dearees before vouspindle can be used on tbe Iathe, but thjs two split plates that clamp the spindle in . Mountflat in 4-jaw chuckand centre. go on. If not, make the Jecessarv adi 'st-îndle is different. since we have a full the position desired. The mounting is * Bore out hole to accept spindle ments and re-macbine tbe side. 'a 'hinesplathe spindle nose on this spindle, we can fairly sim ple and flexible. through both plates. the final side to m ake the plates to size.m ount chucks on it. This m eans that we To mount the spindle to the vertical . Mark edge of plates for the four 1764 File off all burrs on aIl 12 edaes of eachcan actually hold thinqs in the Iittle spin- side, the follow ing items are needed. The inch holes. plate. At this staoe the nlateWs should bedIe and use the Iathe spindle to do the dimensions given are the finished dimen- * Centre drill gn 4 Iocations from both to size and you ihouldube able to nut

machining. x whole mass of accessories sions of the parts. sides (8 locations total). them together in anv wav vou olease Jndcome to mind - but not now and not * Drill yk inch hole from each side so not be able to tell t 'at th'e 'e islny differ-here 2 Pcs steel, 4.ooo inches x 2.500 that they meet. ence betw een the nlates.

The basic mountings that com e to inches. plates need to be * Open holes out to :'y- inch and drill ne-blue one pla-e and m ark on it oneind immediately are: ' o.soo inches thick. through. of the four 17s. inch holes on the plate

m 4 pcs steel, o.soo inches round x * Stam p num ber stam ps to m atch the face. M ark this hole very accurately and

. on the vertical slide, b0th horizon- 2.625 inches Iong as units. check your work. First mark the hole unbolt plates. . with a IIght centre punch. 'rhen Iook at itally and vertically (or at any angle if spacers,

la w ivelling slide), this 4 studs o.2so inches x 3.125 inches * Cut plates in two. . ' with a m agnifying glass. If it needs to beyou ave a s dard use. Iong w ith washers and * M ill saw n faces so aIl plates are the moved over you can do it w ith a heaviereing the stan. on the cross slide at centre heightfor nuts. sam e size. punch and a ham mer. Just ham m er the

T ts M aclained. M ake each from * File aII edges. centre punched hole over to where itspecial functions. cross drilling and 4 nuious exam- 0.750 inch diameter x * M ake the 4 optional spacers . needs to be. This hole w ill be used as aeyw ay cutting are obv

ples of often needed operations at 0.375 inches Iong shafting. guide to drill aII the other holes in theThe raw material for the plates is nominal faces of both plates so it is im portant 'tocentre height. . .

' once we have the materials in hand, w e 0.500 inch mild stee plate . vou need get this right. centre drill this hole andwe will worry about the use of the are ready to begin machining. . enough stock to make two finished then drill it through :764 inch. Deburrical slide and Iathe car- 7. 4.000 inch by 2 . 500 inch plates. Try to b0th sides of the hole. Now clam p thepindle on the vert

riage only. .. .. , ' t.. . : '

,.

,

. 9et the m ost free m achining m aterial that two plates together four tim es in the ..

. . . .,ti YOu can find - it m akes it a 1ot easier to four possible orientations and drill

. d . j . (,.y..., , . .. k, , ,, ., . . o the work . Life is too short to spend it through with this hole as a guide. Using

4Q . -.. 41 , , . ,

I .' '

. ,, . , .,. I.. . . ' ' ''. . I '. ., 1 . . '

. . ' ' ' . . . . ,, j'

,

)' jjdillh hhfh4hlN7dill5/ihddhd

7/23/2019 27 - Spindles


,, j ,. , . . ,. , ,, r..) . ' vjjen drill through at each of the 4 holes a No 7 drill 5/a inch deep and tap each end g y3y 4 2.0001' 0.500 . .' I . . . ' '6, kjjj a 1ys4 drill. The slightly Iarger drill is W -28 (see Appendix 2 for UK equiva-

' j. 0.812,', . ;

.. . ' '. .

oWseded jnere to allow the plates to clamp lent) for a cap screw .

: .. k;. t : . : .-r-. ' .' .se spindle without the bolts binding in Make the washers out of machined

.'' ' ' '' ' l ; l l l : . .' ç- lt also gives you a little adjust- 0 . 500 or 0.750 inch material, O.1 25. , . , : E r-7 : E . , tjle holes.' ' . ) : 3 - l . l lE ; ''' . - ent room . Deburr your work. inches thick with a 0.250 inch hole,:, :..,. 0.375 : : : : j r , , , m j ates are still bolted through them for a close fit on the studsl E 1 : R=1 . 1w.. j ' j ,, ,

w hile the p0.125 1 1 . : 1. j g 5... atjisr y use your nklmber 9UNCheS Or a' . cjccz : ...... '....--.--. . . . -- -.. -. . . to . ' ' ' ' ' ' ' ' ' ' ' ' ' g j 4 unch tO m ark a1l the mating sur- M ounting the spindle on the ' .. l E: l 3 l 11 centre p

E : i : : faces that will be created when the vertical slide l l E : 1E .. .,. 'rlais will make The two split plates when assembled toE E 17/64 ; j . '. lates are SaWn apart.' ' '

. ' t h t C) C) t l txges E .... . p ier during reassembly . the four spacers w ill provide a footprint..h . . , $ ' ) â : ) .j. y 4. thkngs eaS. , . , E . E , .. '

unbolt the plates and saw them in laalf that w ill place the mounting studs on a. h ' I. .

'.. . ' ' C: Iengthwise as shown on the drawings. 3 4 inch by 314 inch grid. That is the4.000 ' , ; put aII four halves in the mill or the 4-jaw same as the standard spacing for the

., :' . ..... . . . , . sgure 4.1 Clamp plate dimensions. 'î '.

'' '' 5 chuck and m ill down the saw n surfaces slots on the vertical slide and on the

' . , , l ' for clean up. Remove aIl bolts and file alI cross slide table. The spindle can be. ,. ) ,, , : , , surfaces and edges to rem ove all burrs. mounted in either direction on each of

first plate. Check the dim ension to tbe edges and It is well worth the tim e to m ake the 4 these surfaces .em aining three boles in thewe can now clamp the two plates make adjustments as necessary as the spacers that will hold the plates exactly The goal in Figure 4.2 is to have a very

together with four 1 W inch Iong by 1/0 - w ork progresses. You should be able to 3ys inch apart on centres . ln the m ain, com pact m ountinq that is as close to the2o (see Appendix 2 for UK equivalent) put the spindle into the bored holes with the spacers make it easier to mount the mounting surface as possible for rigiditybolts. Mark the exact centre of the hole the slightest bit of jiggling. The fit should spindle. The spacers should be made of It is the intention of the design that thefor the spindle. This should be done as be a close sliding fit so that w hen you cut yz inch rod and should be exactly 25/8 clam s be near the bearings for m axim um

accurately as possible and it is well the plates in tw o and re-bolt them inch Iong . Centre drill each end, drill with rigidity although that is, of course , notworth the tim e to m ake a centring button together, the spindle is held snugly andand screw the button to the centre w ith a firm ly. W hen unclamped w e w ant it to ; stuu ' :'.6-32 screw . The button can then be com e loose with ease. W e need the hole Nut ,

y Viasher l .djusted until it is exactly in the centre of to be from 0.002 to 0.004 inches over- oams 3'. 'the two bolted plates. Chapter 1 6 con- size. , ' ' ''tains instructions on how to m ake a set ln a design like this the clam ping hole ' ' . . .of centring buttons. These have also should alw ays be slightly oversized - : : : : . ' .been described from time to time in smaller holes w ould m ar the spindle at : 1 1 : i: .

1 E . E IE . . 'odel Englbeer. You may prefer to use a the jaws each time you used them . : I : , : 1: ,.: ,ublished design. lt will be well worth Rem ove the bolted assem bly from the ; l : ; I ; .p : y y

, ,huck and re-blue the 4.000 inch by /2 l . I . . ' : . . , , ,our tim e to m ake a set of buttons. c y Nut : : ,j : jhe two-plate assem bly is now inch sides. M ark the plates 'to drill the : : : : , , .;:,j 1 I

mounted in a 4-jaw chuck. centre the four 76. inch clamping holes that go i j f . JI J , ) ..Iates with the centring button which is through the width of the plates. The i 1i :1 : .? ; .. ,'t . .already at the exact centre of the plates. holes are intended to m atch the slots in ' . , .Make sure that the plates are flat in the the M yford system . These slots are 1F:6 : l : :I : ::. , , '' '* * *

. l : ;l : .chuck. Rem ove the centring button and inches on centre, so the holes need to be . , .'drill a sm all hole at the centre through 3:4 inch apart. M ark these holes from : . '.âboth plates. Open this out to the Iargest both sides and centre drill at each of the . ;'

j 'drill in your collection and then bore it out 8 locations. Drill to the centre of the .' '

, . , . . ,.,

so that it is a nice f it on the spindle body. plates from each side w ith a W inch drill, Figure 4 . 2 cross section of splhdle mounting ..

' . , . ù ' , '

42 i , î . I 43 . . k .

. ,

7/23/2019 27 - Spindles


. To m ount at exactly the centre heighl thread in each cylinder but not all the0 f vour Iathe, you need to make a block .(..-3',. way through the cylinder as discussed E spa'cer that mounts on the carriage . This *'-'.

,. above. Tlae Iast thread should be lef't un-i i E .. s i i spacer needs to be of a height that will ' finished

y,. E E E bring the spindle centre to the exact Iathe ure 4.6 Tnuts formountlhg splhdle. M achine off 0.1 25 inches or as neededE E i Fig5 ; J J centre height. Since each Iathe is slightly for your slots from one side of eacb nut .

..''

E different in this dimension, you will have -rhe T nuts should be made to suit the Set up again to m achine off anotherg j o.E . . . to determine the nroner thickness of the v ol.a's on vour Iathe . The T nuts for 0.125 inches from the other side .

:: : : - spacer for your p -rti Jular Iathe. For refer- ' J'-n-ing th'e spindle to T slots are easy Now, keeping the un-threaded end of l limate thick- to make from a piece of 0.750 inch diam- each cylinder in mind, machine the stepsnce purqoses, the approx

ness of thls spacer is 1 .062 inches. eter rod, First m achine 4 short cylinders in the nuts-. each 0.375 inches tall. Drill and tap a W - Driving the spindle is covered in Chap-igure 4.3 Front view of the mountlhg. As needed o .zso'' 20 (see Appendix 2 for UK equivalent) ter 1 4.

, . j. g . ,' ' '

. . . , ' . .bsolutely essential. If the mounting is to 'tical sîide the studs should be kept ' . ' '' t' '''' . t '' . : ' ' ' Ver ,

. , ' '.. j . . , .. , ' y : h../..... '.... . . , f( . . ' ,, ) ' ., ., .. .s short as possible to avoid interference . . . . . ..

'' h k nd'' t of the Iathe '. . Drill 17/64 : ' ' . ; '.t .'. '' . , . ' .% ' '. ' ''. ''ith the c uc e par s ..

. . ' ,through , , , '

, )., , . , ,. , . j ).hen m ounting to the vertical slide it ' . '. '' ' '' , ' ' . ' ' '''.: .' . '':' . ..'. ' . .h h ' '' ' ' chamferedges .'' ... . '('. r .k ' '1 '': ''' i t .' ' ' ''' C tEê ''; 's often necessary to make sure t at t e . ' . . '

axis of the spindle is orthogonal to tne pgure 4.4 optional spacers forplates. , '' ' . . ' ' . 'axis Of the Iathe. This is best accom - ' .plished by confirming that the slide is ' ' ' .. ''' ' . ' '. 'actually parallel to the face of the chuck Since the loads transm itted by the ' ' '''t' ' ' ' ' ,

and parallel to the cross slide before spindle can be controlled with the depth ' . . 1m ounting the spindle. of cut thal is taken, it is possible to use ' . ' ' ' . ',71- ':The cross slide should be m ade parallel four spacers instead of a block. These ' . '.' ' ' '' . ) ', . ' 3,

to the chuck face by bringing it up to the spacers can be 0.750 inches in diam eter ' .' .'' '.. ' . . '' 'chuck or a face plate as it is being w ith a l'Ji. inch hole in them . Longer . . . . t:. â, ,. '. . . ' .. .m ounted. W hen the spindle is mounted studs w ill have to be m ade to allow the '1 l . ' .':to the vertical slide its face has to be clamps to be bolted dow n with the . . . ' : . ) . i ht angles to the bed This can spacer in place. ' '' , ' ,7. ' ' ' i '' ' ' ' '). . . 'a e at r g . ,be done by using a m achinist s square .betw een its face and the bed of the lathe. ' . ' ' . '.'-' '

W hen m ounting to a sw ivelling vertical ' . , ''.. ' ' 'slide it is best to m ount at 0 degrees with ' . ' . , ' . , t

Figure 4.5 Studs for mounting spthdle. . . , ' . . .the swivel set at O degrees and then to ' 'adjust to the angle that may be desired t è'with tbe swivel. Tbe end of tbe stud that fits into the :' ' ' . , . ' . . ' . :. . . . '' ' '

nuts should be threaded so that the stui .-' ' '

M ounting on the cross slide w ill not go aII the w ay through the nut. . .' .' , ' :, ';' ' '' ) Iide alm ost invari This keeps the nut from breaking the slots ' ' '' ,.. ;îounting at t e cross s t .'' . , ' . .. .ably m eans that w e are going to mount at in the table if over-tightened. It is also ; i ,'

' (the lathe centre height (if not, w e use the w orth thetrouble to make the nuts so tha - . . -*These are avail able from various suppliers,ready made orthreaded . A.J. Reeves & co tB-iaam) utd orertical slide to attain the height that we a stud cannot be threaded through them

A. Marks (Model og) are two suppliers.eed or to make a cutl. , .).; . kï., ;. pastthe bottom face forthe sam e reason,

44 4s

are bar makes it easier to m ount thedflfhhh

that were used on the cartridge spindle

7/23/2019 27 - Spindles


CHA PTER 5 ,, squ d;e to flat surfaces that have the ?.,, ,j, , spin tjartj v sjots cut in them . It is. . .' ' . . ford Stan: , vyso easier to clamp a rectangular sectiona f strange setups that ama-o aII kinds o

' r engineers find them selves dealingtetl

., . .,;, .: : . wit .S 11 r rs Note ingone front bearing allows us to liminat

sm aller overhang at the front of the use a

t F S I I spindle. This is desirable for stability dur- ng heavv cuts. .

yhe general construction of the spindleI felt that this spindle design represented the m ounting m akes this effectively 2 follow s the construction of the cartridgethe smallest spindle that one could m ake m uch sm aller device. soindle. The emphasis in these instruc-and still preserve the No 2 MT and thus This spindle is sim ilar to the basic snin. ti'ons is on the differences between thetbe Myford collets and tool holding fea- dIe but omits the ability to mount a chlck cartridge spindle and the small No 2 MTture. Tiae spindle fits in a 2.ooo inch by on the spindle nose. Doinj that allows 8 spindle.2.ooo inch steel bar housing. smaller spindle to be fabncated that car About 2.000 inches in from the big endlae cartridge spindle described in get into sm aller- tighter spaces. of a No 2 MT, the taper is Iess than :/4chapter a is a relatively large spindle for The m aior chance in the desinn of this inch in diam eter and so can be m ade to fituse on a small Iathe and can get in its own smaller s 'indle is fhe omission Jf the rec. in a 0.750 inch shaft. There is not a Iot ofw ay w hen w orking in close quarters. A ister that centres the chuck on the sniW m aterialIeft but there is enough for ourpart of the problem are the clam shells dle nose. This allow s us to reduce '-hi Iight duty spindle . That dimension is thethat m ount tlae spindle, w hich althouah outside diam eter of the snindle frorr basis for selecting the inside diam eter ofvery versatile, do take up a Iot of room .-ln 2

. 250 inches down to z.ooo-inches. Th6 the main bearings to be 44 inch. Thesethis next design, the m ounting is formed spindle can be made either w ith a rount bearings are sm aller than the bearingsby the housing itself. Although the 2.2so body that is 2.ooo inches in diam eter olincla round housino is replaced by a 2.ooo housed within a square bar w ith a sectior jinch square laousrlng , .the elim ination of 2.ooo inches by 2.ooo inches. using thi

l I 1 . . .. j . . . . l I ll .. ' * '' - ) I

.I, .t j j1 . ..1 I - - - - - I k 1

3. 125 inches on centers I.' j 1 .. ' w

, I I . . j1.562.. ' 1 ' 1 y , . I : , s-

1.r1 , c . Iv 1 -('- I : I ) -' .- j I . I'' ç - -I 1 ' - . . - '

, I,' j

I I ,; - - - - j . - I2 Morse Taper I I 1'-. j . . - ' j 1 I

1 : .1 I I('- 1 ' '1 ' 1. :1

te-' 1 ) 11 IJ 11ta La

Figure s . 2 Front vjew ot. spindle , . '? thchessqsare

Figure 6.1 A smaller No 2 Morse spindle housed ?' a 2 l'hch square bar houslïw. '

46

and thus the outer dim ension of thehousing is reduced. M ore im portantly,the m ounting slots can now be m illedright into the spindle housing.

Elim inating the register for the chuckalso elim inates the need for the flangethat the chuck tightens up against. Thistoo allow s the spindle to be m adesm aller. However, w e still have to pro-vide a shoulder for the bearings to

tighten up against and a sm aller flangeface to protect the bearing seals. Theoutside diam eter of the bearings deter-mines the outside dimension of the sqin-dle. lf you can find sm aller cross sectlonbearings, this outside dim ension can bereduced further. I picked the ''easiest tofind'' bearings. W e w ill need about O.1 25inches of material past the outside of thebearings on aII sides to allow for thethreads for the bearing cap.

The spindle cannot be m ade anyshorter because w e still have to be ableto span the table that w e will m ount thespindle to, on the vertical slide. One sidehas to clear the cutter and the w ork andthe other side has to clear the driving pul-ley. That pretty m uch sets the Iength.How ever, there m ay be an advantage inmaking the spindle longer - it w ould bestiffer. You m ay w ant to consider this onyour spindle. You w ill still have to designfor slots that are 1?/1e and 3% inches oncentre.

W e will m ake the com ponents of thespindle in the follow ing order:

1 . Buying the bearings.2. Front bearing, inner race clam ping

nut.3. The spindle itself (the part that

spi ns) .4. Block style outer5. Drive pulley.6. Front bearing cap.

housing.

47

7. Cutting the pulley grooves. you can hold it squarely in the 3-jaw . it. So aII finished w ork has to beose On Diametertobe0004inchIess

7/23/2019 27 - Spindles


g p yg8. Cutting the notches in the bearing

cap a nd be a ri ng n ut .9. Cutting the keyway in the shaft and

in the pulley.1 0. M aking the No 2 MT.1 1 . Final assem bly.

1 . Buying 1he bearingsAs usual, before you do anything else,buy the bearings. In this case the inner

diam eter of the bearings is criticalbecause the dimensions are so tight. In aw ay this is the squeezed version of thebasic spindle in the previous chapters.Do not buy a bearing that has an ID ofless than 0.750 inches or an OD over1 .850 inches. The bearings that we needare as follow s.

y q y jFace and cham fer one face. Reverse inthe chuck and face and cham fer theother face - this w ill be the true face thathas to clamp up against the bearing. W ew ill identify this face by the step that willbe m achined on to it. Drill a ?4 inch holein the disk and open this hole out to0.700 inches in diam eter.

Cut threads at 24 tpi in the bore. Theseare to fit on the threads on the spindle

shaft which w ill be at 24 tpi on 0.74:inches. Once the full threads have beencut smooth dow n the inside crow ns with

Bearing dim ensions

Front beanbgOutside diam eter

lnside diam eterThicknessShieldType

1 .750 in (45mm)

0.750 in (2Omm )0.437 in (1 2mm )80th s id esLight duty or deep

grOOVO

Rear beanhgOutside diameterInside diam eterThi cknessS hieldTy pe

1 . 5OO in (38m m )O . 6 2 5 i n ( 1 6m m )0 . 3 7 5 i n ( 1 Omm )Both sidesLight duty or deep

groove

2. Front bearing, inner race clam ping nutThe first thing we need to make is the nutthat clam ps the inner race of the frontbearing .

The nut is m ade from a slice of freemachining steel 1 .250 inches in diam eterand 0.375 inches long. It can be made inthe 3-jaw chuck. File the edges so that

e with centres at both ends. How-Onr you can hold the one end in the 4-ve ,

w for a while. Do not use the 4-jawaain once you rem ove this first setting.gHold the blank accurately in the zbjaw .sure that both ends are running true -e

is im portant that both centres be in linett both ends of the spindle. Face the partnd drill a centre in it. This centre has to

be Iarge eno ug h to al I o w a 34 i n c h hole to

be drilled into the centre and still haveom e centre Ieft. If you do not have aIarge enough centre, turn the centre. Drill

some em ery paper m ake another pass a W inch hole in the spindle as far as itw ith the threading tool to clean up the will go, open this out to 0.375 inches inthreads again. Cham fer the first and last stages and m ake it 3.500 inches deep.thread w ith the threading tool. M ark the This hole m ust meet the M orse tapef andtrue face w ith a Iine across a diam eter. hole put in from the other side.This can be done with a cutting tool set Turn the spindle around in the zpjawat dead centre. W e will use this Iine to and repeat the operations just per-cut the tw o spanner notches Iater on formed. W hen facing far aw ay from thew hen w e have the vertical slide set up for chuck it is necessary to use very Iightal1 our slide w ork. cuts and sharp tools. lf an appropriate

steady rest is available, it should be used.o.2s0'' W e now have a 1 .375 inch diam eter0.812.. dia I shaft with a 0.375 inch hole in it w ith

. - , r .,.740 dia .. x. x Cenlres On b0th Sides .X= 0 704''dia ;' I & Rem ove the 4 - jaW and thoroughly clean250''dia. - - .1 - S j 7 the taper in the spindle nose. Place a cen-24 TP1 Yx .. - tre in the lathe nose. M ount the dog driv-

'

l ing face plate on the spindle and get a suit-0 1250 by 0.125''Spanner slot Qble dOg m ounted to the spindle blank (if

YOu do not have a targe dog, you m ayFigure 6.3 Front bearlhg, inner race have to f abricate one f or this job) . Place aclamplhg nut. ball bearing centre in the tailstock . W e w ill

do the rest of the w ork between centres .

Bring up the tailstock w ith a running3. The spindle itself (the part that spins) Dentre in it to support the work . TurnThe spindle proper is m ade from a piece 0.625 inches of the shaft dow n to 1 . 1 25

f free machining steel 1 .500 inches ir7 inches in diameter Cut a groove I/a inchdiam eter and 6.500 inches Iong. Wide and J40 inch deep 0 . 437 inches from

Unfortunately one end of this spindle the end as a clearance for the threadingcannot be held with a face plate, as w aS tool. Thread the rest of the turned sectiondone w ith the first spindle, because this to 1 1 25 x 1 2 tpi. M atch these threads tospindle does not have the full Myf ord Vour collet closer W hen cutting such

Diameter to be 0.004 inch IessMatch bearing than the ID of the bearing cap.

N. 375*

1.125 by 12 t pi

24 tpiby 0.740...1 1. aezs'.Q31.'0 31 2''

Figure 5.4 Splhdle nose dlïnensions - thereis no allow ance for m ountlhg a chuck.

Iarge threads it is necessary that thethreading tool be very sharp because theflank of the threads gets rather Iarge. It isalso possible to cut the threads in tw osets of passes so that the flank rem ainshalf as w ide. The thread is cut to half itsdepth, the tool is then m oved over half athread pitch and the other half of the

thread is cut. Use your collet closer as safor these threads. These threads augew ill never m ount a chuck so their fittingaccurately to a chuck back plate is notrelevant. Chamfer the threads w ith thethreading tool. There is a section in Chap-ter 1 6 on cutting coarse threads w ith tw osets of passes.

Turn the next 0.375 inches of the spin-dIe dow n to a 1 .375 inch diam eter shoul-der. Turn the shoulder into a 0.31 2 inchw ide flange and cham fer both sides.Polish clean.

This com pletes w ork on this end of thespindle for now . Turn the spindle aroundbetween centres and rem ount the dog tothe spindle, m aking sure that you protectthe threads already cut w ith appropriatesoft materials.

The front bearings have an inside diam -eter of 0.750 inch so we can turn theentire shaft dow n to 0.760 inches aII the

48 49

.'' ' '

I '' : . q . . . $ 'I ' j . : ' , ' ,'' '.: .' .

. h ' p b.' .' tfdit lb tdhlfthd ' hkj

7/23/2019 27 - Spindles


.: : ,' . . tfveading tool, about one and half threads '; aawchuok j. , ' I, , , ' ; . ?, k . . ( . : . j j: j gr () , 0 6 0 i n c h es w i e a n d 0 . 03 5 i n c hes, k; j t'jIj ,.. ' l. .'. k . . ... . . g j4 j ( tjgg g s ,; 1 500 inch ' Y m uz - ' t the threads , their. , ? w jjen you cu

' rowns w ill deform slightly and become Housing .

' .' . 62s x 1a tpi 24 tpj down to jusl under 0.750 inches in diam-. . , eter. Adjust the threads to match the ' ,; j $. . 0.625 inch dia . . 0.750 inch dia 1.125 in small square :,. , . . . : I jjy jz tpj threads On 1he nut lhat You m ade. , .

' s. ' :, ' The shoulder to clam p the back bearing uatne bed$ . . . '

' Flaure s.s snintil. zy,'zw,?n.c,w,u . is 4.250 inches from 1he shoulder f or the .',. .. . .

. . . . g ' front bearings. Check the draw inqs and .I

.' . . ; f . ' ' - '''' . . . :check again against your work. M easur- Figufe 6.7 setong up the block forrnac/sh-

i way to the shoulder behind the threaded The threads are to be cut at 24 tpi. As ing from the front of the front bearing to n9' .nose. Leave about 0.030 inches on the always, go slow ly until you get the nut the front of the back bearing. The shaftshoulder for the final finish cuts. started on the threads. On fine threads, a Should be m achined dow n to 0.625 next in great detail is the preferred hous-

The front bearing is 0.375 inches thick couple of tbousandths or so can m ake a incbes in diameter past this point w ith a ing for this spindle. 'iand we need a 0.250 inch space for the big difference - we w ant a snug fit on the Straight shoulder for the back bearing. Taking the tim e to m ake the block style '':nut to hold the bearings so w e can turn threads. W e need a m inim um of about This Should be a push-fit for the back body for this spindle will give you an .aII but the 0.625 inches (0.375 + 0.250) three threads or I/s inch of threads to bearing and for the drive pulley which will easier to mount spindle. This applies to ' ''next to the shoulder down to the root di- engage. cut a recess at this point to have a 0.625 inch ream ed hole in it. all kinds of m ountings w hether they be to 'am eter of the bearing nut threads. At 24 accom modate the threading tool - this Ctlt 5/8-1 8 (see Appendix 2 for UK a table, to a slide, to a tool post or som e ,

tpi, the double depth of the threads is will also form the clearance for the nut. eqtlivalent) threads on the spindle shaft Iash up you have to use for a special . ,0.070 inches. So we can turn the shaft The left edge of lhis recess is to be just P8St the seating for the bearing. Match project. ' 'dow n to 0.680 inches - this will form the past the bearing seat. It should be barely these threads to the nut purchased to The raw m aterial for the body is a pieceshoulder for the back bearing. This bear- wide enough to accommodate the dam? the pulley and 1he back bearing. of free machining steel 2.000 inches by ', 'ing has an inside diam eter of 0.625 Thls com pletes the outside of the spin- 2.000 inches x 5.250 inches Iong. These ' ''inches. W e will cut the shoulder for the dle excep't for the keyw ay. W e still also are 1he finished dim ensions. ,'sm aller bearing Iater. Right now our inter- . need to m achine the No 2 MT in the spin- Do not finish face the tw o ends of theest is in fitting the front bearing and its dle. W e will do lhat in si'tu after the spin- block yet. W e do no1 w ant to do lhis in a 'clamping nut. . dIe has been assem bled to ensure that m ill either - w e want to use this opera- , '

W e can now fit tbe front bearing. Turn . tbe M orse taper and the spindle axis are tion to confirm that the block is m ountedthe bearing seat dow n to 0.750 inches to . . . '' Dom pletely co-linear. accurately in the chuck. First m ount themake a bearing a push-fit onto the shaft, ' piece in the 4-jaw as accurately as you ' 'Rem em ber to use a cool shaft and a 4. Block style outer housing can. Use a dial indicator to m ake sure 'w arm bearing when making the fit. You l Will not describe the m achining of a that opposing faces are equidistant fromcan get a better fit it you take the time to A round housing because, for other than its the centre of rotation and use a machin- .do this. This is critical on Iarge parts but dim ensions, it is identical to the m achinist's square Iaid on the Iathe shears to

ing of the basic spindle housing . m ake sure that each face is perfectly ver-ven on relatively small parts like these s gure s.6 Detailat the nut that clamps the jt is easier to m ake the round housing tical w hen you take your m easurem ents. there is a noticeable difference. ynerrace o/' the frontbearing . Note how t/)a o an jt js to m ake the block style housing

, Once you are satisfied with the setup,Before we cut the threads, we need to clearance for the êhraaJfn .q tool extends to u t tjjon you do also have to make a set take a very small cut across the face of 'have the nut they willfit to at hand. That just under the :ear/hv andhow the crowns ofw as the reason that the nut was made the threads arejust a bit smaller than the Of Clam shell holders for the round hous- the part until you get to a diam eter of

iirst. beanhg ID. D9. The block style housing described 2.000 inches. If this is centred perfectly

. . . r , ,I I . $ . , , .50 , , . jj. .

' ' : r . .; '. . .: , , I . . .

.

on the face of the block, you have it right ing Iater w ork. It is also a reference thal Lightly cham fer all edges and go over (b) Recess for nut

7/23/2019 27 - Spindles


and can go ahead and face the centre of we can centre on if we ever need to .j1 surfaces with some 40O grit emery Bore out the recess for the clamp for thed ut in a centre . (Face the mount the body accurately in a 4-jaw ''aper. bearing inner races. This is a clearancehe part an pentre only , to avoid m aking an intermit- again. Some w orkers claim that a rotat- P T urn the block around end for end and recess and does not have critical dimen-

tent cut that might move the part in the ing centre is not quite as precise as is a do the other side just as you did the first sions. The aim is to clear the nut by aboutjaw s, Once the centre is in place, you can fixed type, but for our purposes, pro- gde , keeping in mind the changes in the 0.050 inches or so on aII sides.make the intermittent cut.) lf not, adjust vided the rotating centre is of good qual- dimensions. The finished length of the 'the part and take another light cut to see ity , it is more than adequate. To some body should be 5.062 inches. W e need (c) Beanhg recessif the centre is right. You have to be in extent this type is better able to take up the unturned portion of the block to be at W hen using the bearings as a guide in the

.the centre from all four sides. There is 1/$6 forces engendered by expansion of the Ieast 3-% inches Iong to allow hold next step, make sure that you do not getinch or so of extra Iength on each side to work as it heats up than are fixed cen- down bolt slots that are 3/8 inches on them stuck in the recess because youplay w ith

. Keep in m ind that the finished tres. centre to be cut into the block . These have a Iot of m achining to do after cut-i to be 5.062 inches long. Rem ove the centre and drill a /2 inch slots m ust not interfere w ith the loca- ting the bearing seats . lt is best if theock sOnce you have the centre drilled in the hole at Ieast halfway or as far into the tions of the bearings - study the draw- bearings are not in the housing when you

body, put in a ball bearing centre in the block as your equipment w ill allow you to ings to get the design firmly in m ind . do this so that they do not get contami-tailstock, to support the far end and face go. Bore this out to 1 000 inch diam eler Drill a 4 inch hose to m eet the hote nated w i'h sw arf . Be sure to use thethe part. Again, you need to use the cen- halfway into the part . Next, using the ffom the other side. Bore this out to spindle as a holder and guide forthe bear-tre suqport because you will be taking rear bearing as a guide, bore a recess that 1 .000 inch diameter halfway into the ings when you are test fitting them. Useintermlttent cuts and these have a ham - is a tight push-fit on the bearing . This part to m eet the hole from the other side. the tailstock to keep the axes aligned.m ering action that tends to m ove the part recess should be % inch deep or about 4 There are three distinct recesses that Using the front bearings as a guide,in the chuck. The solution p:s not to over- inch deeper that the bearing is thick . The have to be m ade on the front end of the bore a recess that is a tight push-fit ontlkqhten the chuck (and thus rts' the spindle is designed to allow the bearing housing: (1 ) The recess for the bearing the bearings. This recess should be /8chuck for fu ture work) but to use a cen- to m ove in this recess (there will not be cap , (2) the recess for the bearings them- inch deeper than the bearing is thick. The

ddo ,f nkqht much movem ent) but the fit should be a selves and (3) the recess for the nut that bearing outerraces will be clamped in thisre an .Turn down 3/a inch of the block to very firm push-fit .

If you overbore this holds the bearings. recess. If you overbore this side, you w ill2.000 inches in diameter. Cham fer the side, all is not Iost , you can open it up for First rough bore the front of the hous- have to start again, so be very careful.corners of the block. W e w ill need this 3/8 the Iarger bearing at the front of the spin- ing for these three recesses , then finishinch as a surface for the fixed steady dur- dle housing . the recesses in the order described be- Lightly cham fer alI edges and go over aII' (

, . . , '' low . Surf aces lightly W ith som e 4OO grit em -/. ï . . , ery paper.0.906 in 1 ,032 in' ' : 5.062 inch overall L (a) Threads This completes the lathe work on the

.

. ,, The dîameter of 1he bore for 'the cap housing., ,'' '. ' threads should be o .oo5 inches Iarger Remove the housing from the 4-jaw$', . , than the outer race of the bearings and and qrepare to take it to the milling

.. ,.y:' ' Bearing Q.1 87 inches deep. Cut a threading tool m achlne. First m ark the locations of the 4?t?.) Back bearing recess Nut clearanc clearance recess at the inner end of the slots that you are about to mill Then

' ., - - - - - - - - - - - - - - - - - - - - - - - 0.187 inch bore and thread the outer part check them against the surfaces on. ,.. ' 1.062 inch hole in housing oa fru .y ea-a- of this bore to 24 tpi. W e w ill cut the cap w hich you are going to mount the spin-

' . . . -s -e J'-'tHtcWGo threads to fit this thread so the finished dle. Only then, cut the 4 slots for the diameter of the threads is not critical. mounting bolts. The slots are to be W +The thread form is critical and should be inch wide by 0.406 inch deep and 314o 2sc in wide slots made as close to perfect as possible. w e inches apart on their centres.

'Cut this recess and the threads first so Go over the entire housing w ith a

' This housing is to be made of 2.0 inch by 2 . 0 inch bar stock. ' that the seatings of the bearings willnot smooth file and emery paper and clean it. . t. ):? ... , f:, be disturbed once they have been cut. up. Use the file to cham fer all edges.' 2,,.,, t, , ' , , Figure s.8 Detalïs o/'hotzs/bv. . , . This completes the outer housing. hf ' lw ' , . . . . o

52 q 53;

,' '

' . ' I . . ' '

As stated before, the m achining of the needed. Provide a threading clearance he housing straight and to m ake sure forces are higher w hen using a Iarge pul- i t

7/23/2019 27 - Spindles


tround housing is sim ilar except that no after the $4 inch for the threads. M ake pat vou can get it back out again. Iey so this should be taken into consid-mounting slots will be needed. Please re- this 0.062 inches wide and 0.036 inches w hen the bearings are clamped tight, eration.fer to the detailed descriptions in Chapter deep. jaere should be about 0 . 030 inches First m achine the finished outline of the

h basic spindle for details. Drill a 4 inch hole through the part and t een the cap and the housing. If pulley and then machine the pulley on t e tw bebore this out to 1 .1 27 inches. Check this there is too m uch , m achine the front on groove. The included angle of the groove5 Drive pulley against the spindle nose - this hole tjae cap w here it touches the outer race should be 40 degrees and the w idth of thexA pulley 2.000 inches in diameter is should be 0 . 002 inches Iarger than the of the bearing. If there is not enough turn groove should be such that the top of the '

shown in the draw ings. The pulley spindle at the bearing shoulder. It should back the shoulder until you get it the w ay belts sits even with the pulley flange.should be made to suit the uses intended just barely clear the spindle so that the vou want it. Chamfer aII edges and First rough machine the grooves with ab the user for his spindle . Since the tw o do not touch w hen the spindle is run- ' olish .

tool with an approxim ately 4o-degree .,p

spindle is capable of heavy work, a Iarger ning. Any space we allow is a door for Now hold the housing in the 4 jaw and included angle. Then set the com pound 'pulley arrangem ent m ay be in order for dirt so keep it as sm all as possible. Do not get it running exactly true . Turn the face over to give a zo-degree cut and cut onesom e users. cham fer the edges on this hole. Polish of the cap dow n until you have ?4 inch side on one groove. Then cut the other

, ' .the surfaces but keep the edges sharp. exposure at the outer edge. Chamfer and side with a -2O degree cut. W iden the .

6. Front bearing cap Cut 24 tpi threads on the section just polish. groove slow ly until the belt seating is 'The bearing cap is m ade out of a slice of m achined. W hen cutting relatively fine W e w ill cut the notches for the span- t'ight . Only then go to the next groove - iffree m achining steel 2 . 000 inches in threads, there is a problem with the ner Iater w hen w e have the vertical slide you try to do aIl the grooves at once, youdiameter and 0.375 inches thick. This is threads suddenty becoming Ioose . Fine se1 up. . are m ore Iikely to m ake a m istake. 'm ore than we need but we w ill m achine threads are ready w hen they go on but ' Once the groove is right, chamfer aIIthe excess aw ay after it is rem oved from they are still relatively tight. By the tim e 7 . Cutting the pulley groove edges and polish the entire pulley w ith lthe Iathe. The threads are cut to m atch you sm ooth the crow ns and clean them The pulley groove is to be cut w ith the 4OO grit em ery paper. ' .the housing threads and are at 24 tpi. up, the fit w ill be perfect. That is w hat we pulley mounted to the spindle and the '' ,.

Mount the part in the 3-jaw and face it. want. work will be done between centres. It is 8. Cutting the notches in the bearing ' 'Turn ?/$e inch of the part to 1 .850 inches Test the cap on the housing with the helpful to have the belt that you are going cap and bearing nutn diameter (0.100 in diameter m ore than bearing in place. The bearing m ust be to use in hand w hen doing this work . The Set up the vertical slide w ith an angle .the OD of the bearing). This w ill provide m ounted on the spindle w ith the back design calls for belts that are 3/8 inches plate on it and cut the two spanner slots 'enough m aterial to cut the threads bearing in place to m ake sure that it is in w ide as the w ide end of the ''V'' If such on the bearing nut you m ade . The ''>belts are not available to you, you might notches should be /8 inch w ide and /8

. . . '' ' . ' yy want to consider changing the dimen- inch deep. Make the cuts by moving the,. '. , .

. I I I I . .. - . . . ;:.. :' sions so that they fit the belt that you vertical slide up and down. File off the .

. ii j i' j . , , . , : intend to use burrs.. ,, . . . : : : g . . uount the back bearing and the back Using the same setup , cut the six slots. z tmo kn dka .

' . ' I pulley to the spindle and tighten w ith the in the bearing cap. These slots too should 'ulley nut - this should be done only be /8 inch wide and /8 inch deep..000 in dia p

't . I ' ' ft h ke way has been cut in the , a er t e 9 .1 0

. 750 in dia shaft. W e need to use the key to m ake 9. Cutting the keyw ay in the shaft andeam 0.625 in

Stlre that the pulley does not slip on and in the pulley '- - - - - - - - - - - - - - - v. - - score tjje shaft w hen we start the ma- Detailed instructions for cutting theChining process. keyway in the shaft and in the pulleys

1 Set up the Iathe to turn betw een cen- are given in the Chapter 3 on the baslc: ' : I tres. Be sure to protect the spindle from spindle.

' the dog when you clamp the dog to the' ' ' spindle . (If using a stepped pulley the 10. M aking the No 2 MT 'o.62s inc: ' . ' .$' Spindle should be assem bled w ith the Next drill a /2 inch hole 3.500 inchesI 7 L . ,..t .,i, . Figure B.9 Drivlhg pullev. ,

, Iarge pulley next to the bearing ) The deep to clear a No 2 MT, You do not need ,

54 ; ; éy

.1.;t'

to drill aII the w ay through - aII you need the clamping nut onto the spindle . c P ER6sthespaceforthetaper h b kb h h ' ''

7/23/2019 27 - Spindles


c P ER 6s the space for the taper. Put the back bearing in the housing .

v ' ' '

Rough bore this out to accom m odate a Put the spindle through to the front and ' ' i ''

No 2 M T and ream it for the right depth the back bearing from the front and put ' ' '' '' ' '

.

for a No 2 M T collet. Detailed instruc- the pulley on the spindle . Place the nut ''' '. ''tions for doing this are provided in Chap- on the shaft to hold everything to - .

r'' ' '

ter 3. gether . ' ' . ' '

Put the front bearing cap on the front 7 ' '7 ' .'

11. Final assem bly threads and tighten down . Tighten the * * ' ,i ' ' ' ' '' ' 'Clean and Iightly oiI alI the parts. Slip the back nut on the spindle . I F I .' ' 'front bearing onto the spindle and tighten The spindle is ready for use

. .' : . '

. b . , . . . . . . t . L . . t ,; t. . . .. ': . . ' . . . , : . . . . ' ' ' . . ': *1r* 1,1 i t i 1E) j:lp i 1-1 (:j l dil 1* di, 1:)4 1* d l 1E1 4: 1-111L El 1t 1-1 ti, 1 1 1*1r71 15l I I 4: 1El 1L 1 ; 1:) i 1-11 -- 'ë' ''::E(':'iE$ ( EE':)i )(i'j ëlEëjj /(q'). që) ty#:t ) 11:' ')' (Ei (E)7) ( Ekt:l E,1(1 ,lc j 1( ijij. . . ; . Er y -- ë, . r .,(- .., ..--., ..E, (.r.y ,, ( - -E . .

-,) y,E .,t - -,.., , -- j . - - -..- - -. # ..: ,. .:( j c.E. . ;. . :.: . :. ... i . .. . ., .. . . . .. , ), ,. ' : . ., .. . . . t , . . .. :.,.. ,. .î #,? ajo tlaat nara dn Ilnof lj1 w n/'k in tho xm n- lr :(:t ' ''tJ' .' ' ' ' ' : E. , . ,

. 'r . ,

', . .

',. . ,

, , .j k ( . , . . ., y .,k . ,. .t ,, ', à . , . ' jeurr s s o p . Th e I i m iti ng f acto r i s th e '; :J

: ' , ' . ' .? , . . , . ' . . t O 2 50 i nch portion Of Spi ndle shaf i n the s 6 .rp . s . . . . t .. ?.$ . . ' , ;;' ,

. : k: , . . .' . . . '

. . . L , . . . . ' bearings. AnY Shaft sm aller than that 7 ( :. . - . .- . . . . . . . .

. .... --. - , ,- -.. ..--.., . .q , , .

, , ., . . , . . . . . . . ,

. ,. would tend to be a bit tOO f li m sy f r ou r ùtrryq l, yè. : :g).j:. -. ; . . . ):'ëf:'î 'tE 'j) ):' Ey'' .:)' ' . ' '. ' . ( . ' .. . '... ' ptlrposes . i)t#(1:t$ :2. ::è . j; :: y.j .)y . ., . . .,,. .... t , . :. ,. ., ,...,$. .. ; yjae m ost intriguing part of this spindle ,,v Ekj-) atxtn?sl) ::. q . , .,. ., ... .. ,j, , . t . ', ,: , . . .

. .. ,

'. ,. js tjaat it f ts in a George Thom as dividing ' :'' C fètfiitili l' ;:Et:2'''C )); :. V . ' . . . .; .. .. k , , . . . .

..

. . . . . .. . . . head to provide instant Iocation at exact .' .' ';E?E'. ' ;r@

ë, k,''1yijEkt j

ï@,)',t,:EIjEE:)i: ,. . . . . . .., . . ,.

'

,, ., , . .. .. .. the Iathe centre height. This is a quickie , '' (, . ,. '

.'V3% ' ''' l''''l)ii,itE)p, ) . . , . . . . . . . , . : . ,. , y . (,j yj(:, :,.. . r . - ë (:;( ):1.'q5.': j ;:: ' . ' ' '' ' .. ' '' .j j :I i:j:1 ) ù, .,. :. . . .' . . . . .

'. . . .. ;j. . prolect - I built one in about two and a : .:.tj:) t @:E',è:: .:.-T: rajk.

' . . . . . . . . . .'

F . ' t . 'z,i ê )(... .. ,:..,.. .. ,, ...; ., ... p :.. . . . . half hours.. . . . . .. :.5 '.. . .

., ;. .. ,,$ ' , , .

. . è , . ., . ' : . '. . ' . k . , . , ) Unf ortu nately, it is just about im possi- :''. ' . t y tj. . . . . . , , . '. . .(î. ,(: y' j . jy:,' y j ' j p((j ' j j ) j y:.:y; ,j.tjy gtjjjj jj (,.,... . , ,... ,, ,, f.. .., .j ble to rno unt the Drernel IM oto Tool (oMT) , . ' ', r.r?: :j t

., r y ( )r:y:q:tE,t.y)E .ityyjr,:,yyj,$jy.y,yyjry:t,. i r ; : , y' j , .

',. .

i . : . , , . ) and Othe r tOOIS I i ke it on a Iathe tool post. '' r ., 8 :' .,' with any rigidity and repeatability . Added Three-quarterlàch spindle mountedl'h

.s . . , y. r . : , ) . - , . a,. ' ,.. . ,t ; . : ...., . : ,,(..,'. ' , ,k .. ) ' . ,. .

..t,; to this is the problem of a rather large Thomas dividing head. Thl% /à the easiest:, :. y. ., ' , . ..r , . . . ..'... . .

.. ' ,'

, ; . . ,., : amount of axial play in the spindles of GaF to 9et a SD?a//'JNWt8// mounted at exact

,, . . . h , . , . . . . , , ' , ,. ./ , t; these high-speed m otorised tools that lathe Centre height.. ' .. ' . : l ' '''. . ' 1 . . 1 . '' . ' . ' 5' . 'r . . . . .

.. . . . . . . ..' (. . . .. . . . . . k.. . ... . .. ., ?'tt ; . . : '') .k. ' .'t/ ,..& . . ., . , ., r . . . ' ; . . . . ' . . . ' . .. .. . ...x. ' ' .

'' 2. @..'' :.', s'.. ' . . : . ,

l'' . , . b ' 4 ,250 inches ' '. .

. .. .''

. .. '.: . '. .y ? h ,.. ... . . . . .. . % . . r ; :. . . .

. . ' . j..( I.' ' .'t: . ?$. . ' :. . C' . .$ ' . '.. .:'. . ; . .

' '. .' î . ... ' .; ' ' ' .( '.,

'

, t 2 , .#.. . , ';. .. (. . : ,) 4 -..' $ . . . . . , r , . . k .: . $ ( ,; $ tyv. . y.,'..., , , . . .. 0.750 inch dia.

,. yhk. . ; Ir k . . .' ' , ;. .: , . :..) '.. . . . . . , j.,. ' ,, ..

) : . .i . .

.., . $.. . .. j . .. y. . ? I yjguye 6 . j SectiLm aclpsg the mjc/r spjndle .

'. ' . . . , . .:. )L' ) .

lt6 ' 57ti .1

'

( $1:7.1('. .' I, '. : I' '.j '. '

kes their use problem atic. The m icro ?r 7'',' ' ' th if you ingest it Do not w eld or sil- the bearing w ith 0.00 1 or 0.002 inchesa ureaé ,spindlew illm ounteverythingthatthe ttkti j uosolder) orsoclearaIlthew ayaroundUse

7/23/2019 27 - Spindles


spindle w ill m ount everything that the ttkti . j uo. solder-) or so clear aIl the w ay around. Use' ' lrkYltrlkstt4tk yptyg@:,@@yr$q'A@tl11>t' ') #/jEE'ii'.i V*'* dentally, free machining materials Loctite anaerobic gjue to hold the bear-e Ine I M oto To o I vv i I I h o I d a n d yo u c a n i:j 'l ky, , , 7ulul, , ,y $ f t: yyy j );. -:- t::., ,,:sp - ..y,:s ylityyjs jytigqj tyEtktl yjz-ot '.4t(F ,,? 1 n c i

>11 'l 'ï Fi ?. 'b è: ' ' ' ' p ': 7 : ' yjE t sï s .)y) c : . . t jtpy t jtt j yyyjtgq ykj,rjzëjjry d o o ot vg e I d w e l l . l n l a y rn a ' s t e r 'n s t h a t i n g ' s o u e r r a c .se it on the tool post of you r Iathe vvith- 1C;Ij: #q s): E:Lr$)$ë)E iti ti zttk y. ryyy . :y.)yj;jj yy:yyjygjy ;

..;y. jyjoj,y yyyakss jy aasjer to ryjacjaine rna kes C h arnf r al I edges . Polish up yourt'j.j.j t .

?'.(.j : j.j ygj)tE: yy' .).h r L : ) '' j) E q,j yjy yjyyyyjj yy

yyy jy yyy jjjjjut dif iculty. It can also be mounted to )tyEjt;r1:E)(;r Et.7yy.à.- ,. jjlp:) s )he Dickson type tool holders with their '1î't1(71)C:':ùlî è:#t$E ' .L?bI- ' - T1i$# ) r: jt harder to weld . The name f or this phe- work.ryi(ttëi):l jsEhë)yy:,ë' t. yy) y '

. îyttttryt j..r ,, ,, j -jjcj.j m eans Turn the work around in the 4-J'awuick change capa bi I ity . Rjj'Ir ;èy)' @Ej))Eijt k' y) /J 7î' y t?lt rkyjyrj'. nomena is Iead shortness wyjyft yyjEj. ,. ry,. . Lyjqsp p tt ykqjjg . ye mejtkng point and strength per chuck and turn the housing down to size .his is a small spi ndle, only O .7 50 .-lktE su.j:.f:ît :.-))) j.,. .- .b -.. j)/$ ' yy s t, yèrjt tjaat t0'

y*j# :)' tf'l: k')k Y) ih) :1 ) ; a jg ' 11t)'' yk fjtyirt ja ce of the m aterial is shortened or The f i nished di me nsion is 4 . 2 50 i nches ,nches in diameter with a main body 4 ( rjEiyjjyjEjjuytëy .tEyj.yjtj yxtjyty ysyy :j, yjjjyjyy-j f orma ilî jtultlïittlk l .jit/#tjn ry

-xg, g.->

yy$yljt tC1) à .

)h) . .r îy y1-fE 1y- )-.kxa. - t tt y E reduced . This i nterf eres with welda bility Re-centre your work and m ach i ne theength of 4.2 50 inches . It uses the DMT 1jt1.ï.)yryk.@ .y;j-t.E)E;.-tt,- . . .. .. - . . . yj yjyys, j syjsg wjtjy yjyoyjoy- yij-jtjtjjjsg oj yj-ja yaosss jn tjae otuer side just Iike you did z/cyjjy s. ,y y jy : , yy j nte rollets and collet closers and so can be kyyyty. .. j yyyyrtryrjyyryyyyysy yrjyyynjy.jyqyyyjyjy (j oo tjys jjrst sjde . on this side the recessl' . .yjlj yttyy

jtllyt.h ,qltlyjykktt.;t. [email protected],l.ë:)t )y#y.t.p ),E,qt tyyjykdjt$ tù t.$:k,y. ,y weI .sed w ith alI the accessories availa bIe f or ljjrjt rlyrtyjjxjy .jyg ryynjjsiyjyyjjyyjyrty yytgyyyjyyjygyryyjytyjgtlrjyyt,jrjyjjyygjrryjo yytr lyjgryy -yljjEyy sjqjisyyjy yz. y jjyj yjya jjousjog js not identical at both should be O . 030 inches deeper than thehese tools . It is desig ned to be used at ït./i 7'l j-.tyz ?;i t:èt :r::= :,k-rr $rièt) ët'))Ii1l#$,t# . u :t..high speeds just Iike one would use the ends - the back end has a 0.030 inch bearing thickness to allow some adjust-DM'r although it w ould be hard to spin it at X// the Components of the % inch splhdle. deeper recess in it ment allowance for the bearing spacers.ao ooo rpm . This and the othersmallersplbdle use jjold the m aterial in the 4 - jaw and cen- Chamfer aII edges, Polish up yourThe spindle is sim ilar to the other spin- 8dhesive' to hold the t7&fOrraO S of the it accurately . The centring should w ork.re ,bearings in place ??? the housings. jae outer end of the bar

. This com pletes the housing.les w ith the caveat that the sm aller de- concentrate on tsign requires the use of m ore z'w atch Face the bar and centre drill it Drill a '

#m aking ' like lechniques and is thus m ore bearings and they are quite inexpensive . 0.437 inch hole a little over halfw ay 2. The spindle ' ' ) ' 'unforgiving of even sm all m istakes. The The sequence for m aking the parts of through the bar. Bore a bearing recess The spindle is the m ost critical part of thesm aller com ponents used allow the use this spindle is as follows' O.1 90 inches deep (to match your bear- project.W e will make the spindle out of a .of the M yford Iathe collets for holding the .

', ings) and 0.625 inches in diam eter in the piece of free machining 0.500 inch steel

parts. How ever, the most dem anding as- 1 . Housing . ' r bar. Check this w ith the bearing held on a rod 5.75 inches Iong. (Since I waspect of construction is the cutting of the 2. The spindle . . ..,

W inch screw held in the tailstock. Using obliged to build a number of spindles andrecesses to hold the outer races of the 3. Spacers . ' f $ ' this technique allow s you to have a han- did not w ant too m any w ith Drem el M otobearings. Free m achining materials are 4. Pulley . . . dle on the bearing and it allow s you to noses on them , I built m y m icro spindle 'recomm ended and brass m ay be consid- 5. Making the spindle nose . guide the bearing straight into the bored with a threaded Jacobs 1 B chuck on it.ered for the housing. It could also be 6 . Final assem bly. hole, The recess should be a easy fit on How ever, I think the Drem el M oto nose is ' 'used for other com ponents except for : v: . ;h.,,;,j, :? j/,,,.(.,, ,,. , , :,,2 more appropriate if you have sm all cut- . ... .h ind Ie itself 1 Housing )):i'?''' '.'': '':t'E)(jiyp.pt '' '' ' ' ' ' ' ' ters and high speeds i n m i nd if not you '.t e S 17 . . .. r ,

. y .yjjyj jyyyjyyyy sy jyjjyyyj j j y-yssty yo jjuyjtj a yy ggsy sqj j-jqj jo j j' The housing is m ade f rom a piece of . ') jî, .t rEt' r,:s(:)tf ,1,E,k: $ft:jLE(:t,?)/h:ttj rea Y, , . . . . . . E .y yj y: yyt ryyysy j .jyyrgjyyrgrjgg zgytyyy: y o u y-jsetj to j.j a ve a D re m e I M oto co 1 I et.. ... o . 7 5o i n c h f ee m a ch I n I ng sto c K * o z :) t ': ' ' ; ,??: .$y..(r ty(t)Cy:j::jE,E', yy:tt.g,y)j.g j j ry o j.j oo j sj a ntj a ya j n c j.l s ja af t . ,PZIZINgS ' '''. ' .'

' ' ' inches long (f nished to 4 . 2 50 inches) . ':7 CE:EEEEîEjEy :#0èjt1J1tEE CI Oser, a.)j;: . ,j ( y yE( yjhere are tw o types of free m achining ,'' ,

'ï'. ,.t l7'?è' E: in hand before you proceed w ith the next

j y j.: ... .,. ,y, .s usual we start with the bearings. The materials that you should know about if '/ 'i?'1fjhgC):. :

: i:' E phase of the w ork. . ... Ahktytyy f(g,t,y set up to work in collets . Start by 'earings I used w ere as follow s- you w ant to enloy m aking a Iot of sm all :qjr T:k,Jj tij:q-'k E

)EEyT:::: y.:csty :yy6:yj:yfpjtC'ïEè1:1E:' ; ... putting the spindle blank in the 0.500 ' .teel parts. one is tlne Leadloy type of , Jtë tu

ty ?(î: , ,. y y, yy,.. , .,, nside diam eter 0.250 in (6.35m m) material that has Iead added to the iron to ;:) èk 1''' :'7':?:':.... .k,':i:t r:> inch collet and centring both ends, then.. ) :'..' : '.7. .. '' E .E:: '@ . .' .. :'utside diam eter 0 . 625 in ( 1 5.88m m ) m ake it more machinable . The other is ' ' ..'' : ..E)t.6)t:., ,::::'VV:è''1 ï'' .' J' :î ) W ith 1 .000 inches sticking out, face and

. . . ( E EL y:ö y'' ' jj':. .. .''' ' E. '''' ''''. lhickness O . 1 87 in (4.75m m) the top of the line free machining iron bar 3''6/:15' E''Y ' 16 i turn 0.750 inches of the shaft dow n to ' J:; ' 'S Is Both sides that has tellurium added to it to further ' ' :' .,')) :(:3E'i: 0 375 inches in diameter so that you cana .4 .' jët'; fE.--- t ?ïE'.:.- . t' -Shields None '' ' ' enhance m achinability . lf you can get a é hold It in a sm aller collet against theNumber needed 2 piece of one of these you will indeed be in The % inch spindle mounted l'n Thomas Shoulder just created. This area will be

clover. LNote' tellurium is toxic and w ill dividlhg head with chuck removed to show turned dow n Iater to form the spindle 'These are very com mon, easy to find give you a bad case of im m ediate garlic V indle housing flush with dividing head face . nose. W e cannot do this right now :

. j.r ,' . . ' j;y : ''. . ' . . .5; 1E, . . . '.

' - , . . . ' . , - .'

. 119k 41.)/ '. ' . .$.. ' . ' . ''1.''' . . '

.,

' t , ' ' ' , 7. 4q ijaa as the bearing is m oved farther and em ery paper. W e will m achine one end0750'' ()250'' '*e jIeft downwhenwemakethefinaladjust-) f rthertote

7/23/2019 27 - Spindles


0.750 ()250 e j, Ieft down when we make the final adjust-. . , ., -) f-- . . . . . ., rther to t e .. . fa. . , . , . .

'. nie cut the threads at % -28 (see Ap- m ents. The spindle should fit in these

. ' '

-7 dix 2 for UK equivalent) tpi for the spacers as an easy fit.. oen,.. . , 2/' . , n 27c,, x 4ctpi rulley nut. Rem em ber that one of the bearing

. Finish the flange that forms the protec- recesses in the housing is 0.030 inches7 i to deeper than it needs to be. Assemble the., , tion for the bearing seals. The flange s

. , have a f inished dimension of 0.250 sqindle, bearings, pulley and spacers out-.

, . , . inches (width). slde the housinj and adjust the unfin-) - - - - - - - - ream 0.125 inch - - - ished spacer untll the housing ends and

. $ . . 3. spacers ' ' 11 ' the bearing ends are the same distance

., . r . , . w e drilled a 0.437 inch hole in the hous- apart. The 0.030 inch allow ance will give -x) (. , . . ' ing. The spacers w e make have to fit the extra space needed to ensure that it. , ,,, .. , k : 0.295'' dia .

'. . within this so we w ill m ake them 0.375 aII w orks w ithout binding.

,' inches in diam eter w ith a 0.250 inch. 460 diaream ed hole through them . The spacers 4. Pulley

Figure 6.2 splhdle nose details (see chapter /6' for detalled Dremel collett dimensions). are best m ade as tw o spacers - that will The pulley dim ension m ay have to be ad-reduce the depth of the holes to be drilled justed to match the drive belt you have inand ream ed. The overall Iength of the m ind.

because we need to hold this end in the exact, it should cut so that the headstock spacer has to be 4.250 inches m inus thecollet. Cham fer aII edges for now to side of the w ork is bigger. thickness of tw o bearings. If the bearings 0 .093., -.n o.375''orto suit your belt

o 1 90 inches thick, the spacers haveake it easier to put this turned part into Keep turning dow n until you have are .a collet. reduced the spindle to 0.270 inches in to total a theoretical length of 3.870

AII the rest of w ork on the spindle w ill diam eter. A slender shaft m eans you inches. That is the theoretical distancebe done betw een collets and the have to take small cuts and use a sharp fOr a perfect fit but w e w ant them to be a 7tailstock centre to ensure that aII sur- tool. M easure again to see how your bit Ionger than that to start with. Check , zsc', dia

Ietely co-linear w ith the Iathe is doing. These m easurem ents tell this w ith your setup. After the spacers 0.250''dia. shaft ''aces are com paxis of rotation. you w here the thick parts are so that you are in place the spindle should m ove back '

d forth in the housing about 0.030 3 ''ount in a 0 . 375 inch collet and Ieave can respond accordingly. en0.250 inches for finishing the flange. The Next reduce the 0.270 dim ension to inches and both bearings should be flushrest of the spindle can be tuned dow n to 0.250 inches in tw o equal passes. Note With the housing face when the spindle is c a7s', (ua '0.250 inches in diam eter. First turn the how far you moved the tool in the first ptlshed back from the front.

Start w ith tw o pieces of 2.0 inch Iong Figure 6.4 Pullev dim ensions. ,em ainder dow n to 0. 450 inches w ith a pass and note how m uch w as cut from

sharp tool in one pass. M ake a note of the shaft. Use this know ledge to m ake an ;nd 0.375 inch diam eter pieces. Hold '' '

the cross slide setting that gave you this adjustment on the second pass to end up them in the 0.375 inch collet and drill a The pulley is turned from a piece of s/ o laole through each one, half from free m achining alum inum 1 .250 inches iniam eter - this is for m aking an accurate at 0.2505 inches. Rem ove the Iast halfassessment of how parallel the Iathe is thousandth by using a file and polishing eoch side. Ream this out to 0.250 diameter and 0.625 inches long. Hold incutting . Polish this and then measure with 4O0 and 600 grit emery paper. The inches. Accurately face aII four ends to the 3-jaw and face. Turn a 0.375 inchboth ends. It is important that both ends bearings should be a firm sliding fit on the be square and clean and very Iightly diameter boss 0.093 inches Iong on thebe the same diameter to ensure that the shaft from one end to the other. It is per- Cbamfer each end using 4O0 or 6OO grlt pulley. Drill and ream a 0.250 inch holelathe is cutting parallel. If it is not w e missible to thin the centre dow n by a bit - through the pulley. chamfer aII edges.have to adjustthe tailstockto make it cut to make the slide easier. Turn around in the chuck and face otherparallel. There is a discussion on lathe once you get the bearing started on œws-oo usc-lo side for a finished Iength of 0.468 inchesadjustments in chapter 16 - read that the spindle on the right-hand side- you seetextorlextsnotes Or to suit your belt. chamfer alI edges.and adjust the tailstock if needed. Get it can use a file and the em ery papers to The groove to match your belt will be cutas good as you can. If you cannot get it work dow n the spindle ahead of the bear- Figure 6.3 Spacerdimensions. Iater. . .

60 ' 6 1 .

.t .fq.',.s' rfh .p)2l ... . .w ' . '' ' '' '' ' f ' ' ' '

5 M aklng the spindle nose Ished nose and satlsfy yourself of accu- '' ' ' ' ' '' 'GetoutyourDrem elM otocolletcloser rateoperation ' ' ' '''

7/23/2019 27 - Spindles


Get out your Drem el M oto collet closer rate operation. . , and go over It w lth a palr of callpers I.e. t .. ,. .....' i ,,... . : ' . ' 7' ' ' ' '' '

k w Its d'm ensions. You w ill be 6. Final assem bly '' '-: '. 1:h ' .'. ' ' '

' ' ' ' : ' . ' t' . '' 'et to no. . . . . . . 't-. ... . . . .-. . . . .

.ulldlng to your closer s dlm enslons w lth Clean and pollsh aII com ponents. Do a dw b'r .' ' '

. . -..t, . .. . .. . . . . .my notes as a gulde only. run assem bly to m ake sure that every- j;), . ,

' .

W e still have the front end of the spin- thing w ill w ork on final assem bly. ' ' ' 'dle to f I I I '' ''

ndle in the collet with the tw o recesses in housing . M ake sure w ' ë 'athe to hold the spthe nose sticking out. Turn the nose dow n you do not get adhesive anyw here it .' ' C ' :'''' .

to 0.290 Inches In dlam eter to m atch the does not belong. W ipe and clean up any '' ' ''t ' ' ' ' ,. . . . .

un-threaded part of the colle't closer. Turn spikls. Let it set. . .'' ' '' ' . f.'.' ''' '.' . ' ''t. . . .the f ange down to 0.250 Inches thlck if Push the spindle through the f rst bear- . ' ' i' ' .this has not already been done. The out- ing. Slip the tw o spacers on from the ï ' . ' ' '' '7'slde diam eter of the flange is not critical other side and prepare the second recess

- 'f ied as 0.460 inches to clean f or the other bearing . Put sorne Loctite in Introduction '' ' . 7Xv.;y7j'V.'lE?'l1C2'1C1l17@ /7lèé1C111/i''C LJî?tC77t':171@i$7/,r@l:1l@?')'1è#f11::117è11qifl-f,trVJ'1EiTnd ls specl. . . )rj.rj.qjj.,ysyy;,y)ryk:j. jrt yyj.: a,:gyylh') 'rr y.y'.î '.v ?rt. .j.?,,Ey,'pIh? jj,g, )' rryjjyo.u j., )h.,# ,)ty ja (.j r:j,. f d ja (.j a a f jj '' ' ' +...tt.t.k) -

tt .j:,I. tj ltkt ytïtlj ?tjjqkpl.qrrttt tt'tè' 't)'t' t''''' .2-3,tfz': .?ttï.k. âqï.-''y ..t$y(:'' )j,Put a centre on the nose and drlll a Sllp the second bearlng ln place and f oI- The splndle descrlbed In t Is c p r .: vz sglgky. 1, . . . . . . . . tkr-. .. .- 7 tlykqi rst :Jr j

. 1 09 Inch hole ( /s4) , 1 .000 Inch deep In low up wlth the pulley and nut . Tlghten very slmllar to the 0.7 50 Inch dlameter y , :y?yt9yts,r@;. j(.yk ?jgy. ... . ,. m . n. .., . .., . I j. . . .a . . . . a., a , . o u . . . ex .,,.. ex ... + .; ..x e ;- s . .z

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ty, yjyyjsyy, yj yyyyjj 6 0 O * n c h e s d e p f o r t h e c o l l e s h a f t . C h e c k f o r f r e e o p e r t 1 o n . A I I o w t h e a d - b 1 l d * n g 1 n S t r u c t n S * n t h a t c h a p t r . O n I y qyj't; yyyyyls.jyyjjkyol njlwny jtty ' tjpjyl oj qj jjkp : j.: ajvï ; j ? ) - . cxoy; .) tjy y y-C I e a nt c nt re a g a * nW - t t e c e nt e h es * v e t o s e f o r 1 2 h o u rs. t h o s 1 te m s n d 1 n g s p c * a I att * O n o n '1CCCV1 V F)>:' 1:* :1'1 EIC =t:%%jy,;i)f1@'t1ti::1sll'1t1htfVï Y'& ' $2V ï ? y ? y,pri' y ' yy jy ?.f tj ,;,(yt,.,,f r, .,.. .. .;:.,s , . ' ,p r kI,t jj tè@glpi. . . . . . . . y.k j j ; ) ,, .. ,y y ,, j g(, yy , ,,. ,j(y.j j.yjy ,,y.yy, j,y

j.,. t rtgy,y?j, y,,yyg yjyy,, . 4 : .y ,j ) g rjj j,y, yyyyy:j j,. j jj j..j j:y)jj jr;jgj jr.j jgjjj .( j r.j jg j je.j j:g)j:jj; jjr gj: j jjjj jrjj jgj jjjj j jr.jjjjjj jz ty )j j j jygj .y jj jj jr.j jrgj jjr j,,jj jjgi jj;jjjr)jj je. jj j jkjj i jjj jr. jjj jgyjjj :jj j:ri jj.jj:jj; jj; jjjj j:j j jr.)j jj y r.j j :j; jg je .j jjjj jjr)jtjr jgj jr. . jjjj jjjy,j yt j ;yj jj ,: yy ,jy,; j jy yyy . , g, yg. y y )yy y yyy yjy-yyy,jy jjjjj

y.yy y

yyy.; jq yyy yjy y y ,y,yy y; jyyy gj ,j..,ygy yyygy yyjyjgj

y,gyyy

,j,jjj, yyjj jjjjj

Cut 40 tpI at 0.270 Inches on the nose supportlng the pulley end In the tallstock, Thls splndle wlll be of lnterest to those 2.3 Vjyjjyyyyj sjjjj jt gjoy. u - . y, ..,v) ... , . . -, ,---- -,$---- ,-----, --,--,,., --- , ,,,,f or 0.37 5 Inches . M ake the threads a cut the pulley groove to m atch the belt who thought the 0.7 50 Inch dlam eter t/tj:ytylzr,yikjy.j.j syjyyyy,kylyg.jyyv , . .. 7)t'. y. .good f It for the collet closer. The threads that you intend to use w ith this spindle. spindle w as a bit too sm all - this Is a .'

m ay have to be slightly sm aller as m ay be Clean up and polish your work . Iarger version of that spindle. The inner The / l'hch diam eter splhdle; a Iarger. m ore .needed for your particular closer. After This com pletes the spindle. spindle diam eter has been increased from substantial version of the spindle descnbedlhthe threads are cut, make sure that the Note that this is a throw away spindle, 0.250 inches to 0.375 inches m aking the previous chapter. Construction methods 'end of the nose has a slight flat on it for You cannot take it apart and fix any- this spindle considerably stiffer. are I'dentical.the jaws of the 3jaw chuck that Dremel thing once the adhesives have set. That ..., ,. . . 1, '. . ' .

provldes. is the price w e paid for ease of con- . 4.250 inches .# ount an arbor and w heel on the fin - struction. )î'' ' ' '

1î' t $.. I' . . . i '

, .t . . ., ,'..? ' .

. ' . ' ' .,'

. ,'

,

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.. .

'' j. ,.

. ' ''.. i djameter. , 1 .00 inches

, .' . . '.' '

) Moto Dremel Tool .' . ' .. . '.

, ,. .' , tk Nose. see ch 1o. . . .

.. .. . . . . '

.. , .s . , f. , , . ,, .. ,, , , :, Figure 7.1 / ?hc/l dmmetersplndle w, /? oremel Moto Toolnose. ,, ,. ... ' ' i

. ' 7. '' '. t.i j , .

62 , t , ' 6:. . . . tr',

Even a spindle 1 .000 inch in diameter '*.RL :) rkjr ,,. . z yy .r j (:j. qj ;gr(5s too sm all to try to m ake devlces to qqy'ttijt c;s''1 c016 47so'' ' osoo''jttsyrj

7/23/2019 27 - Spindles


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. kyl l îr 4lt . : pt. i,; r$ kr. q jtilli ;q y (u v ;.: j'j r t rj ) , (idj ; ?,).LLî; ;3.$z tX. 'r; tk q jj r s'g ,$: ;3 .).j jk)rb.y t:j: jL# t)i ; à., yjrj y jjy ,,. , . 4:2 . 4:2j :E ;::2 j 1.qj ::: ,11 E5, : 1;E5; 11, 1ilL I :;?: IEEI 4:)p1t21- )k 1 ; l 4:j1(E 1E1 171.d: d l t:j l - 3,$.;' à.. u.. .L .t q ?;; r ). k' - - -.4; .sa .t - , . ..:. ,y..h- ..:.,; - ..,.. .. :a r . . ...s -. ,.. : . .. ;. jj . (; qgr jrjojya,

'ï ' ' YC bc SCZIOU . . 1'.;t 1 .260 dIa ,, '' Yjie jnternal COm pOn8r1tS Of the 1 lnch ' '' , '' c ()a2 'nches( , . I I . .. . . j).a5() dja . dlam eler splndle. The smaller splndles use . . ' . ' ' .-1st of ra w m a terlals . .:. ..- .

spacers belween 1he bearings. ' ' - 0.375.' diaescription Diam eter Length . ''' ' . s,. u. '' ' '' . . ' â ' ' ' * êOuter houslng 1 Inch 4.375 Inch '' ' : ' ' .,', e' ' . ' . '' d I considerations I ' ? . 1 .. Pulley wldth 0.375 reamezs mm) (1 1 sm m) Speclaspindle 0.750 inch 7.ooo inch Please follow the Instructlons for the y . z . . . . .. . uelt . . . .w. . .' to sust your(2Omm) (180m m) 0.750 Inch dlam eter m lcro splndle for .;

h. ... .-e . . , ,spacers 0.5 inch 5 .000 inch m aking this spindle . :.''' : . . .

(14mm) (1 25m m) Anaerobic adhesives need about 0 .00 1 ' ' ' ' ' 'julley 1 .25 inch 0.500 inch to 0.002 inches f or the adhesive betw een . : 20 degreest32mm1 t 1 5mm) . 'rjje outer races of the bear

' 't. . ' ' ' F-gure 7 .4 Pullev dimensions. .atlng parts.Pulley nut* 3/8-24 tpi, 1 Ox 1 , purchased . jd with adhesive

. This allow- '''i '.

'.lngs are he ,.

*S A d' 2 f UK e uivalent ' ' '' ' ' ' ' '' ' ' ''e ppen lx or q ance should be allowed for these flts . .k. . , ' . . ' .... . . , . ..

,.

. j .

. 7 '; . , . .f '. ,, ,

.

. 4.250 inches . .. $, ' .. : ,.- ... 2 . ,. '

. ' :.j'l . I .. .)'k,1;r fI 11 z 7s'' totalto stad with ,, ' OD=0.500 19=0.375 Length= .

0.877.' dIa '.c 312'' deep' - - . . . 6:'. Figure 7.6 Spacer dimensions (see discusslon ln Chapter 6).

. . ê j; .r j., , '.' . $ û :1 .. . dd. . ; 'E . .. . . . r 41 : . . '. . .. . . . . , . . ' ' . : . ' '

. . . . . .'

. .,ï ... ,.. , , 0.625 Id 1 .GK jnch d6a . n . j) . vjjey w ijj not be easy to take' ' ) raW lngs eanngs . .

Recess same depth Recess 0 . 030 inches . These sm all spindles are very easy to apart to replace the bearings.as bearing . deeperthan bearing ' ' ' make, have very few parts in them and Do not scale the draw ings - use either

' ' 9o togelher quickly. They are essentially the given dimensions or calculate a valuethrow aw ay spindles that use anaerobic from given d'm ensions. Non-critical di-

.. . . Figure 7.2 Spindle housing dim enslbns. ' I adhesives to hold the outer races of the m ensions can be m ade to suit your needs.

64 s

, ,

@-?

. .

. , ..

..'2 , . jyt oéraw matenals This is a substantial spindle and is

CHA PTER 8 . . ' ' Y . ' ''' ' i tion Diame4er Length shown with a spindle that will accept the . . 2 , ) ; nescr p' ' ' ' ' '

7/23/2019 27 - Spindles


g pp) p. .

. . , : . , , , . .. .. . .' , . . k jw using 1 . 250 inch 4.375 inch JZCObS 1 B chuck - this chuck w ill hold a . cuter'. , ? . ; ,

,.- - 2 (32mm) ( 1 1 2mm) 0.250 inch tool . A Iarger chuck and a

. .' ' ' . '

: ; ; . i ,.. .k s ,

. .,,

.k . . gjjjstjje g.y5g jncjj 7 pggg jncjj Iarger driving PUlley could have been ac-

.. .. . . acers 0.625 inch 4.000 inch longer and m odified to accept 4.000 inch Sp. . . : j (16mm) (106mm) grinding w heels on a half inch arbor See

q : o I éo r c j j j pujley 1 .250 inch 1 .000 inch drawings for the 1 500 inch diam eterI . I u : hw : w . . . (azmm) (2smm)spjndjes to see how this may be done.

., . I Pu jje RU t * X - 2 0 t 7 i , 1 2 X 1 . 2 5 , ' ; ,, j :j. .

'.

. urchased ln mY Oginion this is the smallest su ) .. . : . .....,..'; .,:. weaoaoaendjx 2 for ux enuivalent Stantial'' Spindle. However, it still uses) . . ,. ' . .. . .' I ooo '--v'- = adhesives to hold the bearings in place., , . ,.. .. . . ..

'

, kaj considerations and I felt that a serious spindle should not. , . ' j spec#. . .

.. ,

' . .,.... fallraw ,so i,ao+rnolia,a. ylar ls. be designed to use adhesives so that it' r 'wu-- '-''-- --- .---'---'--- .-' --- can be rebuilt over the years .Introduction '' ' Even a spindle 1 .250 inches in diam- 0.750 inch diam eter micro spindle for

eter is alm ost too sm all to try to make ar- making this spindle. oraw ingsThe spindle described in this chapter is rangements to clam p the outer races of Anaerobic adhesives need aboutin very similarto the 0.750 inch diam- the bearings. At these sizes I thought it 0.001 to 0.002 inches for the adhesive DO nOt scalethe drawings - use eitherthega

ter m icro spindle in chapter 6 except for still best to use adhesive techniques .betw een m ating parts. The outer races of Ziven dim ensions or calculate a value .e hesive. This from given dimensions. Non-criticalhe diameter dim ensions

. Please refer to Once we get to 1 .500 inches in diam - the bearings are held w ith add tjaese dim ensions can be made to suit yourhe detailed building instructions in that eter

, other techniques can be used m ore allow ance should be allowe onhapter. only those item s needing spe- easily and the time investm ent required fits. needs. 't

cial attention on this spindle are dis- starts to pay off . .

cussed in this chapter. 4.250 inches long , ' '.his spindle will be of interest to those Bearinj selections '. . . , ' . ' . ' )t '' .who thought that even the 1 .000 inch Quantlty 2

diameter spindle was too sm all. This is a Outside dia. bearing 1 .1 25 in (28m m) y .

Iarger version of that spindle. The main Inside dia. bearing 0.500 in (1 4mm) ' . ' 'spindle diam eter has now been increased Thickness 0.375 in (1 Omm) - - - - - - - - - - - - - - - - - - - - - - - 1.250 in dia .' .from 0.250 inches to 0.500 inches. This Seals 2 (both sides need 0 688 incla dia thru hole. ,makes this spindle stiff enough for more . . . to be sealed) 'serious work. '

' ' 0 500 inc.h dia ' '. ' . ' . .'0.250 inches ' j/2 . 20 Recess to match ' Recess 0.030 in ' .

.. nut y bearing ' '. deeper than the . . '

., , . j . ., , j . , , , gearjna used I

.. .. ...... .. ..

j . ' . , ''.. , .' ' '

. . Figure 8.2 Spindle housing dimensions.. . Tbreads and ' .

. . ,' . ''' ' ' ' . ' ' ' '

re is e r to y 2 l ,J . . .'. . 'r '

,' . . '. .

matoh chuck pujjay to match '' ' )6/,' . . ,', ..

' ' '.' '

., ,

'

, , . . . . .'

., 1.250 inch dia 0.688 clear hole mo hllf Io lw n.oa . . /1 ' , ' ' '' ' ' '

, . , , ' ' J .j ' ,' , . ,.', ' . ' . . . .

' ter spindle with Jacobs /8 chuck threads //1 ,,i''' 'igure 8.1 1.25 inch dlame ; .. , I ,

can also be m ade with the Drem el M oto Tool nose on lt). .. .' . '. . ,k '' i b ' . :r ' ' '. j ( ' .

66 (. 1;: : .

ç.

HA PTER 9w 5.875 inches . ' .'?

7/23/2019 27 - Spindles


. ? .. . ..0.625 in , .. ' . . ' ' . ' . .

0 500 inch dia push fit , ' ' ' ' ' ' ' 'o.2sc in . î . .y . .

' ' for bearings .' j .. ,$.,'. .'' . . '.' ''.'' ' . ' ''.' ..' '' ' ..3 ' .' '' . ',' . ' ', . .i ' x' .' '' '

t t 1- st, ..' . xz .

1/2-20 tpi threads for 0.5 inches . * * * .... q . . . . . .,

,.. . ..'. Threads and register ',k ', ' eI I q I l ' ., . ' '. . .. t h the chuck '.' ' t, s R * K M * K $ . . , '. ' . ' . ' to ma c . .

. : ,. ,..l, . . .to be used . ...' z ' :' , , .. ' . ' '

' ' . $ $. r. . . . . '' ' i ' . . ' . .' 17 .

z 1. Ir '. :' : Figure 8.3 Spindle dimensions. . . I

. : ' . ', ; : .. . .

'

. . .. 2. i W e now shift to making two high-speed make it w orthw hile describing the twof

' ' grinding spindies. units separately.' ' . ' , j ? .. .. '. ' ( j : ' M y interest in ciock making created a Tool-post grinder spindles have to run. . : . . : 1.250 in dia need for a w hole host of new tools. at relatively high speeds for a sustained. , , , . .. . ,. ;

. , . . , ' ' ' Among these are a number of spindles time and cannot usually have conven-) . ' ' 0.094 in 0.468 in .',

' '. .

. . , . n :2s in du , i, , that are needed specifically for this spe- tional seals at the bearings. Friction at.. I cialised w ork. the seals m ay create m ore heat than can

1 l '' '' Two spindles designed by m e w ill be be dissipated during operation to be gen-''

described: one for external grinding (this erated which, in turn, creates specialj 0.500 in ream- - - - - . - - . chapter) and one for internal grinding problems for the am ateur engineer. In

-1 (chapter 10) The spindles themselves industrial applications this is handled by' - - ' ' ' ' are of similar design but the method of using Iabyrinth seals and (even pressu-' j .

? holding the grinding wheels and the sizes rised) mist coolant systems. We could f the w heels are different enough to use a simplified non-contact sealing. o

. . q pulley groove to suit. ' . .E , . f . ' :' the belt to be used .., . ' . . '

. ; . . . . . .

q Figure 8.4 Pullev dimensions. 4 .000 inch housing . ,. . . t , (

' q b .. . . . ... . - . . .,i '

2 000 x 2 inches 1 .500''. ' . . ' .f

Figure 8.B Spacer dim ensions. Make wheel plates to suit j scc jn oo .'.. ,'

. our wheels Match the ' . , y . .blotter panels On Wheels '' ':'' .

. ( C; Figure 9 . 1 The external gr/ht//èlp spindle for approxlïna telv 4 /bc/l diam eter wheels.

y. '.L.' '68 69

.

' ) '

em en: bu1 mist coolants are out of grinding spindle used by an am ateur engi- orks is acceptable for our ''one of a 1 Outer housing.rrang wthe question. Not having seals really neer to be about 240 uses (twice a k'nd'' projects. 2. Bearing caps.

bl hikb hf1O )fb 1O i

7/23/2019 27 - Spindles


causes too many problems to think about m onth for 1 O years) of about 1 O m inutes , 3. Inner spindle.(immediate bearing failure for one) so we each, of 2400 mlnutes (about 40 hours). Materials needed ' 4 . Bearing spacers.w ill opt for sealed bearings and accept W lth a Ilttle care thls splndle should do yjae follow ing raw m aterials are needed 5 . Pulley. xthe f act that we cannot have long grind- that. to make this spindle . As alw ays alI sleel 6. Nu1 for pulley.ing sessions w ith this spindle. The spindle is designed to use a 4.000 hould be purchased as f ree m achining 7 . Key and keyway f r the pulley.

The spindle described by Professor inch or sm aller diam eter w heel and to run steel . 8. Finishing operations.Chaddock for the Quorn tool grinder is an at between 3000 and 5000 rpm . These 9 . Plates for the grinding w heels.excellent spindle f or our applications Iim its are placed m ore by the grinding n escription Diameter Length . . . . (Aty . vith one exceptlon - It uses sprsng w heels avalsable than by &he splndle . ex o . . 1 . Om er houslng . . . . 1 Outer houslng 1 .50kJ inch 4. 1 zu incuoaded bearlngs that are essentlally (as bearlngs . The m axlm um safe operatlng (aa

mm) (1 :omm) AS alw ays m ake the parts that have thefar as w e are concerned, and for our ap- speed for each w heel is marked on the 2 B earing caps 1 .500 inch 0.375 'nch internal threads in them first and thenplications) Ioose in one direction. If we wheel by the manufacturer. (a8mm) (lomm) make the parts with the male threads tocould guarantee that we w ill never grind The spindle is designed so that the 1 lnnnr snindle 1

. 000 inch 6.500 inch fit them . This means the housing has to . . . . -'. . . - * ' ''''''''' ' - T-''- - ' - - - - - ' - - - -

.ln thls one dlrectlon (as he could w llh 1he grlndlng wheel ls as close to the front l26mm) (165m m) be m ade before the bearlng caps , The . . . . . .p . ' . . @ p .'auorn) we could use h1s splndle but that bearlng as posslble. Thls Is lmportant 2 Bearing spacers 0.625 Inch 2.000 lnch houslng ls Identlcalat elther end, each

we cannot do. both for rigidity and for keeping the bear- 11 6m m) (50mm) end holding a bearing that is clam ped byThe modifications I have m ade over- ings clean . The Iam inar air flow at the 1 PulleY 1 .B00 inch 0,900 inch bearing cap .

' I as wheel 's intended to sw eep the air from.

t38mm) (25mm) . . d e from a piece ofom e the above problem as slm p y,g o,x .-. . a - . . The houslng Is ma

'ble '.e. this was the sim plest the near bearing and up to the w heel pe- 1 NUt fOr pulley zz-zw tpl, 1/. x I .u, . jj . d.am eter a nd 4.1 25ossl j lased stee 1 .500 Inc es ln . . purc . . .chem e that I could com e up w lth . The rlphery. Thls feature should be preserved g K ey for bearing l/ax % 3m m x 3m m lnches Iong. Hold the houslng In the 4-scheme is not ideal but the design does by builders. brass is r ecommended jaw and centre as accurately as you can.allow the bearings to be feplaced with wsee Appendix 2 for UK equivalen: V ake Sure that the part is parallel to theease in the future if undue w ear should Bearing selections spindle shaft - if you do not get thisoccur. l estim ated the useful life of a The bearings selected are as f ollow s: righl , 1he bearings wibl bear a: one side

.The parts should be m ade In the follow - only and prem ature failure w ill resultï . . ,ttly ittt t ygyyjyjqyyjtl ter.t- tyyy--yy.juyyyy y

jnryc l,ye - Quantity 2 ing order f or ease of f abrication: Place a centre in the end and drill this out'' ' -f ) E.-''7 'i rE- ',t , ë' i y

(lr)p - yë jE t L, j--jgrt. i j: tpgp(,(;.: ,.$jFpg;, . py ,,jjp- y,r,y r-,- E IE ; a Ir. n t:gjp 4:::). IE::)' -1.. ::E3 ';;,- E1; - n 4: ::E5r -t1;. m lpyj yjj,, y jrij yt jgy j ggyr y yy yjr g jyj y( y yy yy,j j jgy yyy . y y y jyy;y y y. y jyyyygyyay. a y, y s . . .4y.j y ygyj y,yjy yyyy ygy yyy yj yyjtstjvyq ort.l tlt'g y tlrr, .

4 kj:fy jtttyrt.r fëjfuy.ryy yjlyyyyl ijyxjyyjy.y.jo,: ,,., Be a rl ng I () o . 5oo I n ( 1 4m n ) . . . . . .1 ' 7-1 1 -.: E y) n gt ,t ttl, ? yj:,<p.(..y,.rJs ,;se ,, vjaiokness 0

.37 5 in ( ' tlr.nrnl . . ' ' . , .lsygyët,lFlkEt, tlt -yjyy ,yrjjj .yy.- yt jyt yjj yjt yé,y y yyyyyyyyyyyy y yjjj-yj , ,'''lt b.lbtvv 'E,j,yy--ièt.pj: ytq.. yjqt jE t - ,; ,l/ptuë,E't Jttyï ytjy lyjrjy ytt- t-r,phj) j yyrty.tkjlyyljyyEgjryEyyj.ztyyyx seals Inouble s eals ' t... , 4 .

000 inches overall c 1zs inch ' ' 't Fytk E ë l zf- ..-? . t;p;j ëj:., :, $,yt p y;y. y tt yy,j tly jy.: , yjEjr ty ssyjj y jEj g y.s . ;,,ër , .) 1ylti ï E tlrif $'.A' 1h -- yk t j. yj$j .yy t,j .jyyjyj yy. jryyiyyjyjyjgyr j y,, ,j. , .,,E)))tF j (:? jëy t ) : jy .-11), . . ë . ;y , y y jyyj y, -yy :j y jy yyj y yjj .

,,, . ,

;jCystr t ;.y ,Ey ?t . rpr j)i :'j ) y y.t . t E Ej g (ytj) r t é.o ' tittjél:tjq jjëtk j y jjj sjlyyyjs yjje key to g etti ng the bea i n g s to f it . $t ' '' ' 'z , . s ''t . .; .yt ,. . IE, of j ) s.: j j -t ,,j. . - .; ,. .,.E., t)jo ,: '$';( jtl t?t t'.j t:, tt tlj tj tïji j tttjjjj j T' p' . .. : 2 4 t:&wtjlejx y4 yj- (jy: yj ..:ju.a t yosj. eyjjjyyyyu., p r. op e r 1 y I s t e u e o f a n a dj u st a bl e ( by , L'? ' '.# : itL.t 1. .c jy . ljy a$ . .. y j ; 1 j jj :; 4,4t24 j ji jjyyy .jspy? . y . , j. zj jjy gj gj y y.j ,zyysygt Ljty, .4 rjtjttaj ttjv prjyty tjy sjj yo y yj.j aojjjyjj og j sqaooy jjayw usj.j jj.j o yw o j j-yy-jsy y.,, , . .i y ,. .t.t trty:itytrt . . t'-.g.ii-k --txs;t... jj.t z.Elé t t llrt j 'sts./'' ' y $1èt''- J)tyv . ... ... ... ..- ... ..- ... ..- -.- ... ..- .-. ... -.- .-.

. ,tjyttkrss,a /) jy ,u, à'lytrtj'lj ra c e s of t h b r 1 n g s . T h e s p a c r * s m a d e ''.'' To su it 'tvs.. .llyyjttl.t j.yiti.El Et: . j j , Ls.'tï ' 1 lfjrR.ygg. l?: gcili' tt ./zio.''r ,j): 17 1'0 . l 't-'' . .ttg. 7l$Tj??k?lt@2- ,ï.' ,tî: 'Cb .- y'' -fI : , 1 n tw o parts and then one of the parts is , 1ïr bearing ' . '': 11 : .)ht 1? .. ' ' xt

.J@. 8t

1#' .q ,:df e.. .. .f: > $( . arëp#k'lqj#. V6l.kr' .ykt:è:(jt;jpjt 1:'Jjri11.1) ntrpo't1 rnade srnaller and srnal Ier untll the exact ??l ' '' ç 'f'Eyl:ëtjy,lryihï.h - y,.î :;yt,rtj ,.$':,t, )' ,.yL,.y.,y.y CE;; .ùhïhj;t(t@qjdyj- ,:jz.:kuj . . . . . . . -:' .., . , rz t o:;p k j )g) L' t' t.; sjE '):pk .t :s I.jz17Ek.t tt::'9 jjt..éj j: tklo ïtl $hr. :' .J.j;$yv Cç2 ,4tsa>: pkî>l ' kz.r )C,, $ :$ '2: tg 1r 1 1E; 1E1 (:2 1-1 (5 kl' E) 1:jI. -11- 1-)1 1 1E; I 1E1 1-1 4:)4 1L 15 1E1 1,11 El 1* :j 1El 1E; I 1l:, , ,

'.7.r ' j:j .j :: t i jrrj '

.'

,'

.tiëtp? 72i ; , EE i' L't 12r q?'-), :j@ j 231 i -

'. - . . . . :,jxfls.kxtt'vorne z.twzrtt-- qoom q nnrl 1.6 unn rxwor onf +h. .rx ooa. ,x b... .. ev...a : 0.750 inch dia clearance $. ' ' , 7 ..1.

. - F ' 1 (. A,' %* h*' -'* '' . s'All ,/?e components o: the externalgrinding new spacer can be m ade In a few m inutes : ',j( ., Bot: sides of ' ' ' '''.

' 1.. , . . . , , ç I .dle The exterior housing for this sp/wl/e (and you have the short spacer to meas- ,,, To suit bearing the housing are .''' ' ' '. ' î lpl . ( . .. .. ,.

,. . jjg; jj ' ..)t . j; jI . . . r.'. .. .' '.. .h'r',.7s ldentlcal to the housmg of the m ternal ure, to now how m uch was too short ) . r ident ca . . , . .' d' ' dl describedin the next This is not how w e manufacture spindles '' ',', ' ' 'rm mg spm e

chapter. but in 1he am ateur's w orkshop whatever ,'' Figure 9 . 2 Outerhousing dimensions - the ends are ?'8enf/-ca/- - ' '

79 , : 1 1. /tk

. . . . 0.125 inches .%. . ,4 tni 0.125'' -? .. j 1.500 inch dia'''' ''17 '' '' . ' '

' 1500''di 24i h l 24i

7/23/2019 27 - Spindles


1 500'' dia aee- 24 tpi to match l 24 tpi.

',, ( -w. jyousing threads 380 dia ' ' '

j '.. .' .

' ' ', ' .. '1 375' dia ... . . I . o .co4 larger 00.. di a '

..

, . 1 than spindleI ..; ' Seal .learance Make recess for .. r.. - - - - - - - - - - - - - - 4 - - - - - -

bearinn to suit ' . . .. '.031'' * .' L .' : l . '.

. . . . . . . , . $ '

, , ' , Figure 9.3 Detall at :ear/bp recesses at either end of houslhg . y I . ..

... j j,. .,h . , . , . . . j)$, s .

to 0.500 inches in diam eter and 2.250 2 . Bearing caps ;'' . '.

inches deep. Bore this out to a diam eter The bearing caps are made from the ' i,ik' X---' i .( 0.125 by 0.125 inchf 0 . 750 inches for a clearance diam eter same material as the housing. Two slices ' ./('' 0.281 inch t ' è L ,' ' ' spanner slot ''

W e can do half the w ork from each side . 0.375 inches Iong are needed . M easure ê 't . l ''Next bore and thread the section that the housing and make the cap with the l .

7C' Figure 9 . 4 Beanhg cap dimensions - two are needed.accommodates the bearing cap. The larger threads first - that way if you I ; '

, , .inside diameter of this recess should be m ake a m istake you can make it into the ' ' ' ' '5' '' ' '' :',0.005 inches Iarger than the OD of the sm aller cap . the w heel is held rigidly when is use. finish this w ork w ith no problem s.bearing or 1 .380 inches. M ake the bore Start by making a split collet for the Although we can get aw ay w ith sm aller W heel notes: alI grinding w heels have afor this 0.187 inches deep and cut a caps . A detailed description of how to Spindles for the tiny Drem el Moto m axim um rpm that you can run them atthreading tool clearance recess in the Iast m ake a split collet is given in Chapter 3 . Wheels, a three to four inch wheel run- printed on the wheel. This rpm should not0.060 inches. cut 24 tpi inside this (Blank needed = 2 . 000,. dia by 0.437', ning at four to five thousand rpm needs be exceeded at any tim e under any cir-recess as show n on the draw ing. The ex- thick .) File the burrs off the cap blank and to be supported substantially. The mini- cumstances. A wheel that is crackedact diameter of the threads is not critical hold it in the split cap . M achine a reaister mum diam eter at any point on this spindle should not be used. An uncracked wheel,but they need to clear the bearings and O . 1 56 inches Iong and 0.080 i Jches is 0.500 inches. suspended from a piece of string, will ringshould be well formed so that they will Iarger in diameter than the inside diam - The spindle is made from a piece of when struck w ith a piece of hardw ood.hold securely. cham fer the first and last eter of the threads in the housina

. This is Steel 1 .000 inch in diam eter and 6.000 Grinding wheels should alw ays be held inthread w ith the thread cutting tool 0.005 inches larger than you ne-d (theo - inches Iong. The w ork is alI to be done blotting paper Iike pads. These pads dis-

W e can make the recess of the bear- retically) for 24 tpi threads but it is better betw een centres . Hold the spindle in the tribute the clam ping forces on the w heel.ings next. The bearings need to be a firm m ade Iarger than sm aller . Cut 24 tpi on 3- Or 4-jaw chuck and face and centre The arbor plates should be desijned topush-fit in the housing. The recess for this register as described in Chapter 3 . each end. suit the w heels that you have in m lnd andthem should have a total depth of 0 . 125 This has to match the threads on the Start by making the end that holds the should m atch the diam eter of these softinches plus the thickness of the bearings . housing. Once the threads are right , grinding wheel. If the design provided paper pads. Do not over-tighten theThe bearings are nom inally 0.375 inches chamfer and polish your work . does not suit your particular needs, now plates onto the w heel or there w ill be athick so the total depth of the recess Repeat this for the cap for the other is the tim e to decide w hat you w ant your danger of dam aging the w heelshould be 0.500 inches. After the recess end of the housing . W e w ill cut the slots Spindle to do and design an arbor and Turn the spindle around betw een cen-is form ed, turn the clearance for the seals for the spanner wrench

, in the caps, Iater Wheel holding arrangem ent to suit. If you tres and m achine the m ain shaft to suit(its dimensions are not critical). chamfer when we have the vertical slide set up on do not know what you want , you can the bearings. The bearings need to be aaII edges and polish your w ork . the Iathe. ' leave this section un-m achined at this firm fit on the shaft . If you intend to do

A jrinding spindle needs to have a sub- time. Since we have centres on both high-speed work with this spindle, thestantlal inner spindle to m ake sure that Sides of the shaft w e can com e back to section that m ounts the pulley w ill need

72 ? 7a

' ,ï 'h)I $ .'

.ià') ' .. $ . . .5.312 inches (not overalll) ; ' . ' 3 375 inch o verall to startj6-.. . . ' .

7/23/2019 27 - Spindles


.. . ,.344 inch 0 .031 inch . .f . 0 . 437 inch 1( c .625 inch 0D. - - - - ''- - - - - - - - - - - 0.500 ID ream. . ' tr $q;' t Iey 'J'.. . .. . ., see text for Iength notes. - . ' '(' . . ' ''

, . ty, , gigure s 6 aean'g spacer dimensions. - , , g,. r ,,)y ryk ,, . .. .,. ., . . ' ' f)?,, ' ',y .,r . . ; 'Details of arbor yJ/ . really Sharp by Caref ully honing them mountin g are not 0.938 inch diam eter .500 inch dia ' 0.040 X 1 .7 50 inches jng

. jf you have built the ' 1))k P fi O r to C tl't't given and Shtmld '''' . ? . )) ' uuorn tool and Cutter grinder YOtl W illy Imatch tlw wheels . . o o7o inchesb foreo be used. . ' . 1 ;t Or ' indeed be in Iuck here . If not. just e, . f ; j; m ad e it m i g ht' . center drill b0th ends of spindle '' :l. . If w e take 0.070 inches off one of the your critical cuts are to e .

. . . . t be worth your while to take half a dozen. . ' it spacers, we should be able to tighten' ' ( l ' '' l ..' , . ..

.. . , r, i ht be a bit tiji,t or a bit Ioose at this tlaem sharpened.. ..,. .. . , m g

time and some flnal adjustments will be once you have the fit you want, theo be made Smaller to allow a smaller pul- spacers, the pulley and nut. Clamp one needed. Since we do not want to have to sqindle will run completely freely and you

leY to be mounted. See also the pulley of the outer races lnto a recess m achined i m ake a new spacer w e should rem ove w lll not be able to detect any end play

description for the ID grinding spindle. in the spindle housing with a bearing j , material a Iittle bit at a time until we get it with your hands. Run the spindle for two ap M ake sure the bearing seats to the 1 .'right . That is how to get the bearings just timed minutes at 3500 rpm . It should. Bearing spacers bottom of the recess . Pass the spindle richt in the housing . W arm up enough 'thal you can ee

The theoretical distance between the through this bearing and place the two i 'knother technique is to remove both warm up slightly but it should not get hot.nne r races of the bearings is 3.250 spacers on the spindle. Place the second 1 bearing caps and hold the housing of the If it starts to get at all hot, stop immedi-inches. This has to be spaced with either bearing on the spacer and push it into the $

spindle in the l-jaw and the tail of 1he ately and determine the cause. Fix it.ne or two spacers however, it is easier recess and tight to the spacers . Put 'he k spindle in the tailstock . Place a dial indi- Once the spacers are right, each of theto make tw o spacers. other bearing cap in place finger tight . I cator against the spindle shaft or the pul- end caps for the bearings can be tight-h

e spacers are m ade of 0.625 inch Pu't the pulley and nut on &he spindle ' Iey and move the spindle gently in and ened down on the outer races - doingfree m achining stock. M ake the inside and tighten it down . out w ith the tailstock. M easure how this should not affect the fit of the bear-iameter of the spacers 0.500 inches. The bearing nuts are threaded at 24 much the spindle moves - you w ant to ings. If it does, it m eans that the bearingsReam to be an easy push-fit over the spin- tpi This m eans that one revolution on end up w ith an end play of betw een w ere not fully seated and that thereforedle The work has lo be done in the *-jaw the nut moves il in 0.0417 inches. W e o

.ool inches and 0.002 inches. At that the spacers are still too long.chuck after carefully centring each know that the second bearing that we stage you w ill not be able to feel the play ' 'spacer. The Myford collets w ill not hold m ounted is not seated in its recess but but you w ill be able to measure it w ith 5

. Pulley 10.625 inch stock. Start by m aking 1he w e do no1 know how f ar il is from 1he th e dial indicator. Som e play is needed to The pulley show n is m ade of 1 .500 inchonger spacer 1 .750 inches long. M ake bottom of 'he recess . allow an oil film to btlild up under the stock. The material needs l:o be 1 .000the shorter spacer 1 .625 inches Iong or Tighten dow n the second bearing nut be arings w hen the bearing are run. This inch Iong.onger if you have a concern about the ex- finger tight and mark the position of the film w ill elim inate the last bi1 of play M achine the pulley as described inact m easurem ents. It w ill be OK provided nut relative to the housing. Now Ioosen ' w hen the spindle runs . Chapter 3. M ake the groove for the beltt is too iong. the first nut aI1 1he w ay and 'ighten dow n lt is very im portant that you w ork with to m atch the belt that you intend to use

M ake the ends of the spacers com - the second nut aII the w ay keeping track sharp tools w hen m aking very fine cuts.

pletely flat and chamfer and qolish aII of how far the second nut had to be tight- steps of 0 . 0005 inches taken w ith a 6. Nut for pulleyedges so that you get perfect flts when ened. If you had to tighten it 1 75 turns piece of emery paper (400 grit) can be Use a X -20 (see Appendix 2 for UKyou assem ble 'them to 1he spindle. to m ake the bearing seat it means it enough in the flnal stages . A dull tool will equivalent) purchased, unplated nut for

1he ntltlean up and check for proper fit. You m oved. tend to grab suddenly and take a bigger the back of the spindle. Turn

need the spindle, the bearings, the . .. .p,,, , ,,,, , .; ,. .. cut than you w anted. Tools can be kept down to be 0.31 2 inches thick. This can. I

. . i . ' '. '. , , . y 54 h

-

l sooincudia c .cz, Io.zlzinch . CHA PTER 10 '' '* '' ' 1 0 562 inch ' ' ' .875inchdia '

7/23/2019 27 - Spindles


. 875 inch dia .. , . ... .'f

... . . . . :.; ,. 625 inch dia ' '' .' ' ' '

1.500 inch .in . Ream 0.500 .

. . . g.j . . . . . . . . . . . . . . a , , j j j j j . g j g u g jg j #. . : .. . x,. ' 1 ' .

. . . @ K K j j * . z c j j ) j 4 r j R j R S j R g g g s j R C ; . pujjey groove to) E . . , . 's .y ' . t jj our belt ' ' ' 2 ''... 97 , . , , . .

ma c y,' i ,

.* o o # o . j j . $jigure 9.7 Pullev dlmensions. .:.. . . I u u ç u . & J ., :.... . ' . ,

. . t . .

' ': '1. 1 .. .. .' ' ' ' ' $6 .. ' ' '

be done on a bolt held in the 3- or 4-jaw 8. Finishing operations The design of this spindle @. very similar * This spindle has to run at abovechuck to ensure that the faces Iine up W e still have the caps to face and to cut to the design of the O D grinding spindle 1 0,000 rpm so a sm aller pulleywith the axis of the nut. . the six notches for the spanner wrench. described in the Iast chapter. Please refer needs be provided at the driving end

' Hold the spindle housinj in the 4-jaw to that information for details of con- of the spindle (or a Iarger one at the., . . . ,. . o 312 inch chuck and centre it. Machlne the face of struction. This chapter concentrates on motor).

',' '

the bearing cap to give you a flange the machining of the quills and other dif- @ The spindle quills are designed for' . .' . O.1 25 inches thick at the spanner notch. ferences between the spindles. use with standard Dremel Moto Tool

xin' : : Chamfer each edge. The clearance The differences are: collets, closers and accessories.,Jk .j .. .

., betw een the flange and &he housingf:, . ,' .'.'. should be 0.032 inches. Cut the spanner * The wheel m ounting arrangem ent The arbors for this spindle are designed

', ' notches as described in Chapter 3. has been modified to allow the to use the m any grinding wheels and ar-heels to be mounted at the ends of bors provided by the Dremel Moto Com-standard o.soo by 20 tpi nut ' W9 Plates for the grinding w heels ' rem ovable quills that can reach into pany as a part of their hobby Drem el

Figure 9.8 Pullev nut dimensions. M ake the plates to match the w heels that sm all recesses. M oto Tool offerings. These pre-mountedyou intend to use. The tw o plates that go y ?,on either side of the grinding w heels can ' f ') 4.000 inch housing7. Key and keyw ay for the pulley be made from either W inch plate or from (, ' '

File the key for the pulley from a piece of slices cut from bar. In either case first ') ..2:scrap brass. lnstructions for cutting the machine each blank to a flat plate W inch .

keyw ay in the pulley and in the spindle are thick and 2.000 inches in diameter w ith j?lïgiven in Chapter 3 on the basic spindle. half an inch hole in it. The hole should be .k; l .soo'' close fit on the spindle slaaft

, ,.''

- - - - ..- - - - . - -etails of rqor .ext make a collet chuck to hold the . - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Iates and machine the cross sections to Xourlting o . 3?Fg. . .- . . . .'s00 inch pmatch the draw ings. M achine the recess

s in sq first and then the taper out to the outside ,,ç'?)--I 0.12 diameter. That way you will have no diffi- # .k:culty holding the plates. These plates can ''

Figure 9.9 Kev dimensions. F/7, to f/'t be m ade f rom thinner material but that is Rgure 1 0.1 Cross section of /D gnhding splhdle . The parts of the splbdle shown above areAeyeap bv hand. . . . harder to do for beginners. . identical to the OD gr/htz/hg splhdle. ï;. . to.,

76 77 .

..

..'

1' (

u collet and m ake absolutely sure that ytw heels and arbors provlde an Inexpen- Sequence for m aklng quI k

yqyy..q ru . . . . j. . ysjtrygyyy. j gjyys.. yysyyyyyyyy.yyj sjjgj-jt out-of round indication , try re-ve source of quallty g rl nd 1 ng Wheels f r The q ullls are m ade 1 n a Sequence t at ls tuyj :: ; :)yyy u jjj

s )yy j j jjj l dlhd if b OSOf(

7/23/2019 27 - Spindles


s:)y yy, . .u ojjyyyj . . .. . . ) yy ... yygyjr ytyyyys yjyyyyyy w jqjryg tjys taper clean and rotatlng thee I eng 1 ne e r . A w * de Va ri ety of n ot I ntu 1t1 Ve beca Use tWO Sets Of p re c 1 - (ë 7'y t . yy. E syotyy ( g yy yo, jty y yh e 1'n o q?. (:sk. ?. jjj yj jty . . . .. . . . jlave to be undertaken on )/''@r..4ï.t'.'f î> f u can ellml-heels, small cutters and arbors Is avall- slon operatlons yyyt.. ,. yuj.yiwst-jry:n tyy

yljtyyjlëxkytjxtty collet ln the taper to see I yo

jn the United States these wheels are between centres . Speclal holdlng f x- rttkrjtyt?f,. .? . j:: z; yyy,s . .yj y yjyy yy . . j jj-;a sp-y-jajs w jjj ys. 4 jyt) Eg :) ?,.E :. , yyksjjyyqjyj . . . ::ded w ith 0 1 25 inch diam eter tures are requlred . .r Lk:'' tF... . . ?'.1,' t ,ftt,,,t4 ... tt ,7,.,' 't..t41: ï ' ti7alt hjtt, cjse the operatlon o:l rll /I , k ylyjr) ..y j ($) .g: ,y ,j) .L. v..E . yj xyjyyyjyt.j yjrljly j'ljlj.ttk ,ut I 1 n e of the s q uen c e :

.w'.t'i jt:t: - ' . ): ?E t j tytjkjyin p/' 't : ju': jjttl tltlv ttr/i 't - - -rbors . A 3m m arbor would be very close Here Is an o k z j . ,r:-., . , . ..:, ,Lw,j, . x,yàc-Ejjjk juso, ysooaykysjj T )kqj Face the splndle to glve It an exactly-ë ' ( ) (t ) ) k .'),t : z j - t , t . j ' ï - ae, : :- l ..) . . . : . ' '- , - : t 4 - â ' - bv . > - 1 a r ''' '''l . 1,.$ j e r.j g t ..j tj o

,7 4 - n h d .n e eo this size and there m ay be other m anu- ) .'h- /t$tt.:i -r 0 .463 nc, . . '

.113'121 . . 'acturers in Europe who provide 3m m * Declde how many qullls you wouldface. cham fer each side Iightly. Next w e E uropean custom ers - if Iike to have. m e internalgrinding spindle. The extra space ' hat th e quills willrbors for thelr wlll make the recess t ' h

se where you buy w heels, * M achine the recess in the spindle for at the driving pullev is for a second belt fOf . ' 'd ti -hls Is t e ca . m ount 1n. The operatlons are to be I en ' th e quills . higher #r?WJ/KJ speeds' The Second V&?// haS ' 'ou need to m odlfy your qullls to accept caI to those w e wlll use for m aklng the * M ake the 1w o holding fixlures to the tornn;F bar tlsed to install and T'fnove the . .. .' 'he arbors that you are golng to use.. . jaoldlng jIg and test JIg for the qullls. In dI e recess exactly. quills ln lt. Both COllet ()/O.tMS and the &O//& S 'atch the spln

fact, w e w ant 1he face of 1he spîndle and * Leave second fixture in chuck and do are M/a#f bY Dremel' '' ' 'aw m atenalsthe face of the Jlgs to be absolutely ldentl-he following raw materials are needed not rem ove. cal so that the quills w ill m ount to each of - ' - @ Mach-ne t he spindle end of each quill -ï,v-.è't't#;k'rttîkrt'r#î'' #i#tFt't,tt.:t.Eskt.''@ r)r.ktFth#ë,tFî.''z''ti.t'k,k#yt:.'p;#'--'

y.j l: ,.hk ..,k . j:: j,.k -?k - k . .pj L ,:. .t .. k,s yj syyll ; y yj y .y:t t. y , yj (:2j .j L (jj . jj E yjë .. .u. . . ,E.j yyjjty I .. t jj .. y.'.. .y;st (y .yE,j yt(yj @j yj(y j; y ty t,y y y y yyj jy j : .gj. j,yj jgj jgy jg;j j.;j jgjj j jgj j.yyyj jg;j .gj j.y j j j.y jjyj j j.y yjgj.; jj, j,;j jg;j j.gj jyy j j.;j jgjj jgjy..jj j..j j:;jj rjj jgjj kjj ri eqj j:;j jwjj j j j j-qj jjr j- j j jr :j; tl j j j:i rqj ju;j j:i jjgu j (yj . yyy y y .y . . , . y,jyrgjy yj j rj yy jjj j yyyjjj j ?:

,j.j, g.g,jyj, gyy

:j,:.y.ygjrt yyjgj t

yjjy y . y,yy y .jy.j yyj yj

yyjyy y yyyyyyy y

sy, . . . yjy s y.yjjj y yj jgyy yy yjyjysj jyyy

( 114 3 - I-I rql-l ) ( 11 111 (:lp -I-I 1-1-1 ) . . /jjjj . y... t.( ; , :y yjjj yy,j,yjy y j yj yy.,, .. ggyjyjyy yy yg. ,yj,,j jj yyj

yjyj,y,.j.y y yjyyyyyjj

y tgy jgj j j tyy j jy jgy j.yjyj y j jgy jgj ,jy yg;j yjy ,yjjgj yy;y.j jg;j yuyj j.;jwj yjy yg;j yg;j , j.j yg;j . yjj jg;j g;j .j j.y jj j ;j(yjjy .gj j. jjj kgj jyyj jgj jj j.jj j jjjy j,;r;j jjj jgi je;j j j.;j jjr jgi jg;j j j jjj jj jjj j.;jjj . j ,. ., ,, y y,, jjj ,j,v)) yy yj jyyyj yjy ,y . y ygyy ,jj)jq. ) yyyy.yyy yyy yyyy j;yyy jyyyy yjy j. y.y j;yj jyy y. y yy yyyyj y.y j;yj j jyy .

2 Bearing caps .. u a u, .Ij , '. :: t,m ) ( 1 5 m m ) * M a Ch I n e d O W n S H af t O I e a C 1, qu I I 1

jy . ( ,:-gty ve'''%' '# t:.y)t,1..tk ty k tpyj yjyy ,( y ., t ) ) tyyjjy ):y . yy, y-l:: . . t(yt)?(t. .. ( , jj ,,. . âtr.t t: 'yq'lt ftïi 'tf' . ... .k .,& . qïjt t.' j'sj . . . . Bearlng spacers 0.625 ln 4.000 in ozi)tu/j r: :.: ygjtt jyttt: wjjts tlj itjyjjyjyxjtj e jjave to make two holdlng Jlgs - One--'.z' h.'' ' i tq.l 'lj ''( ' l,zis.t't. ttt ' .t .r,?h. ......, .,y.EE. jt.. .t;.t.tr; tjy . .. .j js i ra

( 1 6 m ( 1 0 m ) M a k - n g th e g r * n d r s - n d aytv tt k ;ltîEri: k)?) y. . ..w ' jtstùjjyp jjyjlsyyxj j a a h o I d l n g jl g t o 1'n a k e a I I o f o u r q u I , s ))) y y y, jy ) y y j jyyjyyy yy yoyy.yy .

1 Pulley 2.000 ln 1 .200 in 3-ue main d'f erence betw een this spindle vîil . . . . .- --,u-,s 7:C ,2:.. 2..- .-' yu, y w- arx,.l vs. rxlhmr ax a test f lxture . They'' . eljt. ' .. j.k),) 'tj'?).4 t) : J è '.. + ' m ,tyjy - ' q y c. '' u v .. w w .. .. w

. - -.

-.

( 5 0m m) ( 30m m) . - j . . tj je w ay .rfy ylpr y jyjy.yyj y.tyyyyuEjt/Eh . . . tyyyyyyyytyy s .j ou I d be as Id e ntl CaI as YOu C a n p OS S bIy nd the O D g rl nd e r S p I nd e l S I n j:) jyjj , j y y 4 .ev . , y jy g qyyjysyltjyyy jytttyyysut . ..j N f r p I I e y * 1 2 x 2 t 1 1 4 x 1 . 5 m .

u. .. . .n a n n . 1 l . ,.x oa .j j::j e yxj t d t .. t l '.s -i p 7 kbj, s 9y , . ( ;: :k t: . Ett ljt t y i :) : t j ; .y a r.y.j a k t h e rrl . T 3 e e J I g s a r e t h a v t h e ' jj a t k u o u 1 j 1 o n w w w . .=. - - p yooooyy j jjyjj yj . y jyj yyyjjy y ) ..).))) ))))) y jj jyyjjyjyjjy yyjj yyy ) yjyjjyjj yyyj yjyjyy . j j y ; o s j s y. 6 C1. 1 I I 0 .6 cj kyjttj y, j ,j:. y j;y y t y y s ) : j tyyy s

yyjjjyyjy. ssy.yysygyyyyyjyyyyjyryyjy yt yjyjjyjyy g a x a c s a n -1 e g e o 1'n e a S t e q u l; , jyy j.s y , (; jyj yyy a j j o w y jj a yyj y jy y a yyj qj a yj < r a jy ( a c e jyjjj jjyyjj j jjj y jjj jjjj y yy j

ysyjyj ysyyyyyyyjyyyyyyy yyyyyjyy yy yyyyy yy jyjyy. y yj yyyy yyyyj . jy y o , ya j s y a a s y. o , o j s , jo j.y s y y o

y ' W * t r e p e a t a b I e a c u r c 9 . T h * s r q u - r e S . l 'llik :, ïtt tljtt/kapq ,; . :CU 1 l h 1 I d r 1 . 0 0 0 I n 2 0 0 0 I n ' '' '' ' - - ''' l nthat each quill register to the spindle in ' ' ' j e as w e use f or25mm) (50mm) . j. tjte jngema/ same m ountlng prlnclp# the lnternal cf7/??pD?1f?1fs O

. Key for pulley 0.1 25 in sq keM s'tock 1he Same WaY that a threaded Iathe . . . . threaded lathe chucks: a reglster f or cen- ' glinding S#N5d/O The /0D#W qUlll /& holdtng &mm sq key stock chuck reglsters onto a Iathe splndle on. tring and a threaded section to pull themall cupped grlnding wheel.

,. . .see Appendix 2 for UK equivalent the M yford SB7.uills into the spindle head. Tnls Is a good q, , , First make 1he part of 1he splntBe lhat to m ount parts that need to be w ay i is held in the bearings and the housing ln . (j and rem ounted many tim es.earlngs

. put a centre on each end of the splndle removeee Chapter 9 On the OD grinding Spindle the Sam e way that you m ade the splndlejj .jj M ake two fixtures but do not rem ove n m,.w . -, vu x. . u.= =. Qnd then Work between centres. T e quI the same bearings are 10 be tlsed for TOr 1ne QJLJ grlnuer. I ne Ilnlslleu ulstance . . . tj je second one from the chtlck. Use theend IS to be flnlshed Iast.his spindle

. . f rOm the front of the f ront bearlng to the . dj e is com - 4-J'aw to hold a piece of 3/* inch f ree m a-Once the body Of the spln .f ront of the splndle should be 0.469 . j )e chining steel 1 . 500 inches Iong. Leave It ' l''Sted ' SOt 'tho lathe up fOr uslng t.ttg,,. .,. '. ,. ., ., , r . ? ' t .1.j ,,.i. '. l lnches. Ailow enough m a&erlal to alloW . j e .n a () .6oo inch sticking ou1 of the chuck O.5 inches. Use' ., . . . . . . colle ts . Hold the Splnd,. #.:. . . thls tO be flnlshed to thls dlm enslon.: .

. 7 g . . ' .78 ' 61

i)''q' lj .

0.437 0.312 . 0 . 437 0.312L. ,

' . . jj .I . , , y ,'' .' ' ' ' . t'

7/23/2019 27 - Spindles


,,. . . ..

'('r' ' . ' 1/4-28 threads ''-' : 'y, , ..

. ' 'j .. h . '

. $ 0.750 .. .... ... - .--- - ..-. -- - s gam jo ;,,jr. . ... ..- . . . . . .. - .. . . - . . . .... - - . , .)8'. . .: .? Ream to 0.312 ' , .

... . '' N . ... ':.

, , . t . '.

. - . . . . . ' ' ' '. . .

.

' '. ' 1 .. k' ,...... .'. î)' ' ,.:, Figure 10.3 Cross sectlon of two qulll holdlng fixtures.

. ï' .. '' .' ' . , # ' 0.469*' z E , . ' . .. . :)I ' . . . . . i.yl '

. Figure 10.2 Spindle nose detalls and qulll mountlng recess. . , t kt back and diam etqr f ee m achining steel. Cut all the. .L . $ , , hotder in it, then you can pujj jengths.o more W ork. lf for no otber reason, it is quill blanks to the desired overa

a dial indicator to centre the part accu- w ill get deform ed during these opera- worth it to have a spare chuck or tw o for The two basic quills need to be 1 .500rately - this is to allow us to replace the tions. Carefully clean the threads out occasions Iike this . Incidentally, there are and 2.500 inches Iong overall - overlypart in the 4-jaw if it ever becomes nec- again with the tap, making sure that you tjmes when you should seriously con- Iong quills are hard to use.essary. (Re-cenlring is to be avoided but do not get the tap cross threaded in the sider doing work like this in the 3-jaw and Start by cutting a centre, the mountingWe might have to do it in spite of our best threads. not in the 4-jaw because you can use the threads and registers on aII the quills atefforts so w e m ight as w ell get prepared Face the part very Iightly to clean it up 4 -jaw to do the work of the 3-jaw but not the same time. Next drill the cross holefor the worst now .) Face and Iightly and cham fer the edges and polish the olher w ay around . So if you want to for 1he 0.1 25 inch tom m y bar in all thecham fer the part and centre drill it w ith a sm ooth. W hen you make the quills ,

check tie up a chuck with a setup for a relatively quills. The tommy bar is needed to mountCentre drill . Whenever YOu make a jig, lhat each quill can be screwed down into long time, 1ie up 1he 3-jaw chuck, (or a the quills tightly ln the holding jig f or 1heou should turn a true surface on it that this setup aII the way. AII fits should be face plate) if at aII possible . next operation.can be used for future re-centring (if the without any shake whatsoever. A very Start by taking a blank and holding it inneed ever arises). small taper is tolerable on the quill register Making the quills ' the 3-jaw with 1 .000 inch of blank stick-

Drill with a No 3 drill exactly 1 .000 to ease assem bly but should be avoided. Mount the 3-jaw chuck . ing out. Face it and place a small centre ininch deep and tap the hole W -28 (see Drill and ream a 3/:6 inch cross hole in The quills lhal hold the grinding wheeîs 1he end of 1he blank . Turn dow n 0.375Appendix 2 for UK equivalent) with a the first holder you made for a tom my bar need to be made so that they will run as inches of the quill to 0 . 250 inch diam-tapered tap follow ed by a bottoming tap. for tightening it dow n on the quills as true as possible . M ost users will need eter. Cut a threading tool clearance at theUse a thread cutting Iubricant as it helps they are made and checked. The hole only tw o quills (a short one and a long end of the turned part Using the latheto cut clean threads. Blow out the chips. should be across the unm achined end of one) but if you think you w ill need m ore start cutting 28 tpi on the quill - this w illTake a look at the threads cut w ith a the holder. Here we are talking about the than two quills

, they should aIl be m ade at m ake the threads straight. Using am agnifying glass and try the threads w ith holder that is loose and not the one that the sam e tim e so they will aII have identi- tailstock die holder clean up and size thea brand new high-qualily m achine screw . is to rem ain in the chuck . cal fitting and running characteristics. 74 -28 lsee Appendix 2 for UK equiva-The fit should be perfect - if it is not, get Do not remove the second holder from Each of the quills has to havethe Dremel lent) threads. Make sure that the threadsa new tap and start over. It is important the 4-jaw until a// quill machining opera- Moto collet system nose formed on it on go aII the way to the shoulder recess by .to get this step right. tions, on aII the quills, have been com- one end

, and the m ounting threads for the reversing the die and recutting theW ith a sharp boring tool, bore the pleted. Even then do not rem ove this grinder spindle cut at the other end . The threads. (Use a die with the jackscrew

threaded hole out to 0.300 inches in holder from the 4-jaw' chuck unless you Apace in between is a sqacer and could be that Iets you adjust the diameter of thediam eter exactly 0.31 2 inches deep. need the chuck for another operation . made to any shape deslred by the user. I threads. Adjust it to cut large threads,Ream this out to 0.31 25 inches. The lf you need to remove the chuck to use ahow a straight design . then adiust the diameter downwards un-threads at the end of the reamed hole the Iathe, rem ove the chuck w ith the The quills are aII m ade from 4 inch tiIyou get the fit you w ant.)

80 x ' 81

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'

Clean up the quill and turn down the HA PTER 1 1 '' 'neck. Rem ove the collet closer, collet

d w heel and deburr, cham fer polish up..

-a n

7/23/2019 27 - Spindles


the quill. Unscrew it from the fixture and .' ' ' : '

y '. ' ' .t The first quill is ready for use - - - - - - - - - - - - - - ' ' 'tore . . ... . .. . . .'

,' ' '

,t 'Repeat these operations on all the . ' ' ' . .

quills that you w ill be needing. The only çj . . ,

difference will be in C * ' '.î '' . le o 1 rse ,,uills and their Ionger shanks. AII other ' ' '. .

'' . ;. ï . .'im ensions are to rem ain the same. , , .Figure 10.6 Design sketch for a sm all . ,. ,t, ,. k . .rem el M oto also m ake a very nice u . = , m . . . . . . - . 1 . . . ,small, accurate chuck that fits on these UC'V'H9 *5/W/* IZ Y F Y 11-1 IY . ''' ' .': ''' 'threads This chuck needs a flat section . i '' ' ' '' ' 'at the end of the quill to allow the chuck diameter pulley can be found for the . '' . .. . ' ', . . ''. 7 ' 'jaws to ride on. Cut this flat. You will motor without difficulty. This means wewant to have one of these chucks on need a pulley with an effective diam eter If you have never made a spindle before M T shank can be used w ith this spindle .

hand to hold odd-sized shanks. of 0.697, say 0.700 inches or Iess on the and you need a sm all spiodle , you w ill The taper is draw n into the spindle with a. ' spindle. want to take a close Iook at this design . draw bar. There are no provisions for

Pulley The sketch in Figure 1 0.5 shows how This is a good project for a beginner as a threads on the spindle nose and so noThe pulley can be m ade the same as the you can m ake a sm all pulley for the end fifst spindle . It is a Iight, fast spindle and chucks or nose type collet closers areOD grinding spindle pulley if you do not of the spindle shaft. You can reduce the it can be used on the sm aller Iathes . It is either needed or supported. The bearingshave extrem e high-speed operations in shaft dow n to 0.250 inches for the pul- sim ple and is designed especially for the are glued into the housing for ease ofmind. ley 'to m ounl on and leave aboul 0.032 beginner The com promises accepted in conslruclion.

The sm aller grinding w heels have to inches of m aterial on the belt itself under the design are intended to make the spin- The tooling for this spindle w ould eitherrun at a m inim um of about 1 5,000 rpm to the belt on the pulley. dIe easier to m ake . be cutting tools that already have a No 1cut effectively. The Drem el M oto runs at It is unlikely that we will do this with Morse tapers hold tools accurately and MT on them or are mounted on arborsa maxim um speed of about 30,000 rpm . run-of-the-m ill ''V'' belting. l suggest that there are times when a sm aller spindle is that have a No 1 M T . Tooling for cuttingLet us assum e that w e have a 1 75O we use the now readily available 5 or needed . This No 1 MT spindle is designed clock gears and pinions is available for( 1 45O in GB) rpm m otor for our spindle. 7mm round polyurethane belting stock to have an outside diameter of only this taper Arbors for m ounting drillThis m eans we need an 8 .6: 1 driving and m ake up a belt to suit our needs, 1 500 inches. Only tooling with a No 1 chucks are also available for this taper.ratio between the m otor and the spindle. Instructions for using the polyurethaneLet us further assume that a 6.000 inch belting com e w ith the belting. '' . ' '

4.250 inch overall '

. . ' . t . . . . L' i . . .. ' c '. ' . . . '

--

1 Morse Taper -- - - - - - - - -- - -' - - - - - - -- -. . , 'i

.'. . , ' N

, . . . ' . . L . g . ,

84 85 ,

certain small lathes (Sherline) use this Bearing seleclions ( . 't ''' ., j v ' ections so we have to glue the outer into the housing. The other side will be ; . , , . s; . , d out to meet this .tajer in their spindles. The spindle is best es in place with an anaerobic adhesive bore acsultedtolighttasksandisnotheavy Frontbean'g jaasLoctite Themajordisadvantage Borearecesstoallowabearingtofitinuc

7/23/2019 27 - Spindles


sulted to light tasks and is not heavy Front beang ja as Loctite . The major disadvantage Bore a recess to allow a bearing to fit inucenough for alI but the sm allest m illing cut- Outside diam eter 1 .250 in (32m m) f doing this is that the spindle can then the recess and be flush w ith the outer Iip

o eers and drills nevertheless many, many Inside diam eter 0.625 in (1 6m m) ver be taken apart for any reason. W e of the recess. The bearing w ill be 0 hing is ''Loctited'' into the recess and so shouldseful and interesting things can be done Thickness 0.437 in (1 2m m) i)j not apply the glue until everytwith these. lace and we are sure every operation have a clearance of about 0.001 inchesn p

The bearing arrangem ent for this spin- Rear bearing (sam e as front) b een com pleted - it w ill be the Iast all the w ay around for the adhesive toasdIe is a simplified version of the other Outside diam eter 1 .250 in (32mm) kog that we do . If w e decide to do w ith- flow . This is an easy fit - the bearingharrangements in this book. One bearing is Inside diameter 0.625 in (1 6m m) t the threads ,

w e will not have to m ake should fall out with a Iittle shaking.uused infront and one bearing is used in the Thickness 0.437 in (1 2m m) tjjreaded csamping caps that fit in 1he Polish the outside of the housing. he

back of the spindle. This is a sim ple ads . W ithout the caps is the quick Cham fer all edges at 45 degrees. Thishrearrangem ent that serves the purposes w e There are only 8 parts to this spindle and to build the spindle . com pletes one side.aYhave at hand. It is not claimed that this is two of them are purchased par'ts (the yjae two ends of this housing are iden- Turn the housing around in the 4-jaw .best way to do the job, only that is a sim- spacer is in two parts). ical except for depth - one end has to be Turn it to a lengtb of 4.250 inches. tpIe way to do it and that it works. ' c c6g . inches deeper than the bearing to Repeat the above drilling and boring

.It is not realistic to expect that a begin- List of materials needed . Ilow some adjustment operations and fit a bearing on this end

ner can bore an accurate No 1 M T recess. m arl with the spindle housing . Hold jusl as you did on the other end exceqtThe taper could be bored but it is not oescriplion Diameter Length the housing accurately in the 4jaw and that on this end the bearing recess Isw orlh the efforl. (The tapered pjug true it up

. lt should be true at both ends 0.062 inches deeper than the bearing .Housing 1 .500 in 4.500 in ing and cham -w ould be easier to m ake and even then it aamm) (1 1 smm) to ensure that the two bearing recesses Polish the rest of the housis not recom mended that you try making s indle 1 ooo in 6

.000 in are perfectly in Iine. Face the housing fer as before.one of these.) Unless you have access to (ismm) (1 ssmm) face , centre drill the face and then drill a This com pletes the housing.a ream er (either borrowed or bought) to Bearing spacers . 750 in : 5O0 in 0 . 250 inch hole in the housing as far asdo the job right, I do not recom mend that (2Omm1 (90mm) your equipm enl will allow . The work wil 2. Tbe spindle ' '

jou make this spindle. If you must have a Pulley 2 0O0 in j 750 in start to get hot as you proceed. Use a Iot Next we will make the spindle. The raw D fzf'tRl S-ORRmI d lubricant as the hole gets m aterial for the spindle is a piece of freepindle this size, you should consider of coolant anusing a steeper hom e-m ade taper that is Nut* 0 625 x 18 tpi, jaining steel 1 000 inch in diameteri x 1 .

5m m deeg. Drill this hole out to 0.500 inches m acdraw n in w ith a draw bolt or consider one in diameter as far as you can go . Bore this and 6.000 inches Iong. A1l the work onof the other sqindles. Consider a 20- * See Appendix 2 for UK equivalent . j to be done between centres. ut to 1 000 inch ln diam eter halfway the spindle sdegree (or Iess) lncluded angle as a start- ,ing point for your experiments. W e w ill m ake the parts in the follow ing .

. . . : t ' .

In order to keep the design as sim ple as order: ' 4.250 inches 'possible, the spindle uses double sealed ' '', . ' t 'bearings that are exposed on one side 1 . The housing. .' . '(the other side faces the innards of the 2. The spindle.spindle) . If the seals or bearings get com - 3. Spacers. . : . . jmco', uia clearance hole l .

scc', uia ''' 'prom ised, it is the design intent that the 4. Pulley. ' '. ''' ' .. , . ,

. s ', .

bearings cannot be replaced, the spindle 5. Sizing the spacers. . ' ' t.'m ust be discarded. This decision trades 6. Final assem bly. / ' ' , ,' ;ease of construclion w ith durabilitv. Here ' . . . r .durability is being considered the Iow pri- 1 . The housing z ,i, Recess to suit bearing . '. ' ' ' 'ority item for an infrequently used item . There are two ways to make the housing: .JK p .o...n nsz, assosr . ' . ' s' '

This is true for many model engineering with and without the threaded section ' . . than bearing ismick '' ?' '' l . ' : '''applications, so in a way these are that clamps the bearing outer race in . . . ; '' ithrow aw ay spindles. place. I decided not to m ake the threaded '' ' Fjgure 11 . 2 Housing dim ensions. ' ' ' '

. .. . . . (. 1 ''L'k . t

..

):, 87 6 )$

ï

. . . . . , overallLengthc3. 25 inches to start 4- ?tl11*#0.250 inch 'q y xjja qujjsy sjjoujd ye made to Stlit the

4/50inch 0625inch jkcationsthatyOuhaveinm ind thea;ç)

7/23/2019 27 - Spindles


4./50 inch 0.625 inch jkcations that yOu have in m ind , the. a;ç). juam ().6,5 jncji tjjmeter spaed oj tNe motor and ijle SiZO Of tlle0625 inches dia ..- - - - - - - - - - - - - -

- 41 MT-. - - - - - - - - ..- - - - - - - - - - - - - jo=c.6z5.00.0.750 a 0.625 inch diam eler m ounting hole .

, , . yhis w ould serve most purposes on a' seetextorinormation on spacerlengtus spinulethis size. zhere is only one groove. . 0,875 inch dia () 6gs x 18 toi ..

't On this pulley f r sim plicity's sake. This) . ' ' ' . w ill accept a ''V'' belt that is 0.375'' ' ' '' Ho'e can be o .

2so inch, c.z,2 inc, '. ' Figure 1 :.4 spacer dlmensions.

à ,, .. jncjjes wide at its widest (US size 3L) . 0.7s0 inch dia . or 0.375 inch depending on .f :drawbar used by your collets .' Make your pulley to suit 'the belting that

b . . t .' .'

, . . . , ,.

. W hen making these spacers, the 4-jaw you wlll be using.: ' t '' Figure 11 .3 Splndle dlmensions. , ' b d too tight or the spacers Hold a piece of free m achining steel,. . . .. . , . . cannot e ma eJ . ' . ''

t. , ,, . . , . ,, . , . . will collapse under the pressure as the 2,ooo inches in diam eter and 0.750Use the 4-jaw , and face each end of the should not have to use force because uon hole is drilled and reamed. The reamed inches long in the 3jaw . Face and centreblank and place a centre on each end. Drill have to take the back bearina on and'o -f hole itself needs to be slightly more than the part. Drill to 'i inch in diam eter anda O.25Oincb, 0.a12 ora 0.375inch diam- a few times and eventuallv f Jrce will ruin 0*625 inches in diameter so that the bore and then ream to 0.625 inches to fiteter hope to the centre of the spindle from the spindle and the bearin'

.Spdcers slide on easily onto the spindle on your spindle. It is often a good idea

each side for the draw bar. The hole cut the % -18 (see Annendix 2 for Uk' Section between the bearings. to take a Iight boring pass through a holeshould match your drawbar. euuivalenty threa's on--he Iast 0.67-q lt is critical that the spacers be faced to true it up before reaming it particularly

The spindle geom etry is suitable for aI- in'hes of the snindle . check the thre zrln true so that they will fit to each other and if your drills tend to wander or if theIowing the work to be held by a dog while for a qood fi 0 on 1he nurc-asna' Z * ' the bearings as truly as you can make drilled hole has become off centre for anym aking the part. If you do not have a dog chamfWr the threads .

'- -- -*'Q' them fit. This w ill make the spacing reason.'arge enough, turn o.62s inches of the between tine bearinqs constant for any Turn a 1 .12s inch diam eter bossspindle dow n at one end to fit in your a. spacers qne Iength of spacers. o.12s inches Iong on the part. Cham ferdog. Make 1he spacer as 1wo parts for ease of :#''' ' ' ''2. ' . t .

First w e w ant to m ake sure that the fabrication and fitting. One part is 2.000 '' 5 . 5..'j 4 ' ; ''' .

lails&ock is se1 right to give an unlapered inches long and the other part is 1 .1 25 i ' '= G 1 = r ' . i ' .' ,' : t't t.'q?'i'h :'' . ' ,t Make a finishing test cut along the inches long. Together, to start with, they ' ' ''ê W' l 'Y' l ' $.''' ' ' '. E'''rf''t ' U .

jeng'th of the part and m easure each end. should be about O.1 00 inches longer ..Both diameters have to be identical i.e. than the finished dimension between the ''' ' l g2'000 dia .within 0.001 inches or less of one bearings. M aking the spacers is a ' ' ' .another. If they are not, adjust the tail- straightforward drill and ream operation. ' 7: l : èEstock until they are. If there is to be a dif- Use 0.750 inch diam eter stock. Hold the ' ' ? ' ' ' ' ''' LE o 'ference, the tail end should be the end work accurately in the 4-jaw. Drill and , ' ) ' . ' 'that is smaller (so that bearings gettighter ream each spacer for a finished 0,625 ''f. - - - - - - - - - - - - - L - - - - - -and not Iooser as they move up the shaft). inch hole. Carefully face and cham fer aII i' 1 . 'Chapter 16 contains a discussion of edges on each side of each spacer so 1 ;t ' 'tailstock and headstock alignment. that they w ill bolt up true betw een the ( f 'E ' ' ' '

ijWe will machine the pulley end first. bearing. Again, the two spacers together ' j' : ''. ', ' ' ' 'Turn 5.375 inches of the shaft dow n to have to be slightly Ionger than the space 7. . ' ' .. ) ., ' ' , . 0.625 ream

0.625 inches. Cbeck the fit of the bear- between the bearings. The length will be : ' . . 0.625 incll .' '' 'l. ' 'ings to this shaft, they should be a firm carefully reduced to fit between the 'push-fit aII the w ay on this shaft, You bearings. ' ' ' Figure 1 1 .5 Pullev dimensions.

88 89

edges and polish to complete this side. the fit just right. Bolt the spindle together adhesive manufacturer to clean the and then finish it up With the taper cut-Reverse the part in the chuck and hold now using the spindle, the two bearings parts. Only the sm allest amount of the ting ream er.

bY the O.1 26 inch long boss. Carefully and the two sqacers. Put it next to the adhesive needs to be applied, just There is a detailed description on cut-f t ll i tii ti ft iit h igldlt f tlf tf ght tth t d tigtl 2ft b iidli

7/23/2019 27 - Spindles


g y q ppj pfacetue pulley inanticipation of turnin, it housing. .rlae dlstance from tlae front of anough to w etthe outerrace and recess. ting tlae xo 2 u .r for tue basic spindle inin situ on t'w spindle. vue part t'aat is one uearing to the uack of theotuer bear- girst glue tlne front bearinq into tbe chapter 3, Read that and follow the

ing to form the body of the pulley ing should be the same as the spindle shalloW er recess. M ake sure it seats aII instructions given to ctlt the No 1 M T inoshould be o.soo inches thick, turn the housing Iength. w e will shorten one of 'be way in. w ipe excess adhesive off this spindle.rest of the m aterial aw ay. chamfer aII the spacers by this am ount to net the *ith a paper tissue . Position the housing ,corners and polish. oo not cu& the belt right Qlt

- -on one end to Iet the front bearing set. M aking a draw bar '' '

ove yet, we will do that Iater in situ to Now assem ble the parts inside the push the spindle through the front Make the draw bar out Of a piece of W , 7:6roet a perfecsy running pulîey. housing. The bearings should be flush bearing. Place the two spacers on the or Ya inch rod. Make the rod 0.750 inchesMount the bearing spacers and the pul- with the housing faces. soindle and follow up by gluing the back Ionger than the distance from the back of

Iey on the spindle and 'tighten dow n w ith - earing into its recess . w ipe off any ex- an afbor to &he back of the spindle. Thisthe nut. M ount the spindle between cen- 6. Final assem bly cess adhesive carefully but Ieave enough should be m easured from your spindle.tres, true the outer periphery of the pul- Final m eans final and w e do not intend to for the pulley. lmm ediately place the pul- Cut 0.750 inches of threads on each endIey and cut the groove for the belt. The do it again. Before w e start on the as- Iey and the nut on the spindle and tighten to match the threads in the arbors. Thetop of the groove should be 0.375 inches sem bly, w e have to be sure that everv- down. Turn the spindle by hand to allow threads need to be straighland it is worthwide and the included angle between the thing is just exactly as we want it to b'

t:e back bearing to settle in. set aside in the tim e to cut them on the Iathe to m akeyue pktco of the 'ides of the pulley should be 40 degrees

. Clean and polish aII the parts. Check the a vertical position to allow the adhesive sure that they afe.Take Iight cuts. AII the work is done w ith seals on the bearings to m ake sure that to set overnight. threads is to m atch the pitch on the ar-a grooving or parting tool. First cut a they w ere not dam aged in any way dur- The spindle can never be taken apart. bors that you plan to use. It m ay be nec-

0 4Oo inches deep, then set the ing the handling done in the fabrication essary to m ake a num ber of draw bars toroove.

Com potlnd Slide to a zo-degree angle and and testing procedures. Ctltting the No 1 M T suit your tooling needs.finish cutting one side of the pulley. Then First place one of the bearings on the The No 1 MT is cut in the spindle with the 0.375 inches of the drawbar joes intoSet the compound to -20 degrees and spindle and slip the two spacers onto the Spindle running in the spindle bearings so the arbor being held and 0.375 Inches isCUt the Other side of the pulley. Finish the spindle. Place the other bearing in the that it w ill be com pletely true to the bear- available at the back fOr the washer andbottom Of the groove flat. Use a double back of the housing (the deeper recess). ings. W e will rough bore the taper first nut.Ws-degree tOOI to cham fer alI edges. From the other side place the spindle in ,Polish aII surfaces. the housing and thread the spindle , , . ' ' '

A keyw ay is not needed, we will qlue throuqh the second bearinq. . ' . ë . '''' x' ' .the pulley to the spindle. Slip the pulley onto the spindle. Place ' ' p ' L '' . ,

'. ? ' .

1he nu1 onto the spindle and tighten . , , ' k ,, , .5 sizing the spacers dow n. . , . . . .... . ' , . . . I .

The spindle bearings wil have their outer The spindle should run true and free and . , ' ' , . ' '' ' :'. , 6 '

races held in the housing w ith Loctite. there should be no backlash in the bear- ,, , , h : .. , rL , ' , . , ,'

.

The inner races are held w ith the spacers ings. satisfyyourself thatthis is w hatyou . ' ' ' ' i :and the pulley nut in the back. Both the are Iooking for, if not, now is the tim e to ' . ) .

', ,

'.

.,

'

inner and ouler races have to be the make the necessary adjustments. ': ê.. .'s ' .:,,'''' ' f ' ' '' ,. ;same distance apart for the best opera- ? s,, .. , ;. . r ,. . . )g. . , ... ,. . ,yion of the bearings and therefore the Using Loctite $ jj , . ' ; . . i,s indle As presently constructed the The adhesive should be applfed only aftef );, t ' . , j , , . ,spacers are Ionger than they need to be you are absolutely sure that you w ill never ..t't ., . . ' '' ' :..; ,' ',' .yk' ' ' . .'.'' ' .nd one bearing w ill stick out of the want to take the spindle apart again. k , . ' '

,. .' . . .'

.ousing. The adhesive should be applied to a h' : y ' : ' 'W d t determine exactlyjust how cleaned and degreased recess and race. st ' ' '. '' , '' ' 3' lt 'nee o , . , ;

much we have to take off a spacer to get Use the cleaning agent supplied by the 11 . ' '. '' , . .,,'. ). ,,' ' , . '' )) ' ' : '

' I; (. . ''4) '. 91

90 j :' . é .

CH A PTER 12.. .

'

. ,

'

.

'

'

-.

'

'

. .('',

' è

rlbg specificationsda

gxternal diam eter 0.625 in ( 1 6mm )jnternal diameter 0.250 in (7mm)

Iathe.This m eans that as seen from the 'top

the cutting w heel should be rotatingcounterclockwise (ccw). This in turn

7/23/2019 27 - Spindles


g ) r '. .... , .4 .,. .

y..,. ... ,'.'. . .1' .., . ; .'

V ertical spindle

j ( )yhickness 0. 1 87 in (5mm)seals Yes, both sides

hese are Com mon, inexpensive bear-jngs. Specify a high-quality close fittingbearing, your distributor w ill know w hatyou m ean.

The most serious problem w e w ill

encounter is w ith the direction of rota-tion of the cutting wheel. W e want todrive the w heel in such a way that the

You w ill be interested in this particular as regards the bearings that they were driving force on the pulley w ill alw aysproject if you have a serious interest in designed to use. It seemed that the bear- tighten (rather than Ioosen) the works.Clock m aking. ings w ore out rather faster than w as con- This is a prim e consideration because re-

M aking this fram e or spindle is a good sidered tolerable for accurate work and tightening things in the m iddle of a Iargeexercise in making parts that fit as one ended up with an odd Iast 1:00th on wheel cutting project cannot be toleratedassem blies that fit into other assem blies. the clock w heel I have addressed this I if precision work is to result.Each part has to be m ade accurately specific concern in this design. The fram e Since we do not want to get into the M aking the fram e partsbecause each contributes to the accu- described here has the special attribute business of using Ieft-hand threads and The fram e is m ade from bar stock that isracy of the overall assem bly. of being supported on sealed ball bear- aII the problem s that go with that w e 1 .250 inches w ide and 0.500 inches

A vertical spindle as used in a small ings top and bottom .The bearing posi- need to do som e planning. It is desirable thick. You w ill need about 10.000 inches

lathe is essentially a gear cutting frame. tions are adjustable so that the gear cut- that the cutting take place when the of the material. As always 1 recom mendThere have been complaints about these ters do not have to be of a fixed thick- frame moves from right to Ieft as you, free machining steel for aII my projects -ness. The fram e can be held in the same the operator, face the lathe. See Figure Iife is too short to use any ''hard to use''way as Iathe cutting tools are held on the 12.2. Tbis is as seen from above the m aterials except when absolutely neces-compound slide. Since the cutting forces

- - - - - - - involved in cutting sm all clock gears aresm all, it can also be held in a quick jchange system . It can, of course, also be Gear

cuqer mounted on the carriage and the verticalslide if a few accessories are m ade up. Taifstock

The bearingsThe selection of the bearings is the key tothe design of this fram e. Rather sm all

- - - - - - ' - bearings are to be used. W e need a bear-ing with an internal diameter (ID) of oirection )f0.250 inches. These bearings w ill fit with cutter Movjrnen duriq?

a Cuuxg Opefauona 0.500 inch by 1 .000 inch bar w ith roomto sqare for the threaded adjusters, sothat Is w hat w e w ill use . Figure 1 2.2 Dlkection /W which cutting should take place, Iooklhg down

Figure 1 2. 1 Section across fram e. on the Iathe from above.

92 93

'

or gear cutting fram e

( )m eans that the pulley that drives thespindle has to be on the bottom Not theend of the w orld, but highly inconvenientto say the Ieast, Our belt drive arrange-m ent w ill be difficult if we do not payclose attention up front. M ostly w hatthis m eans is that w e have to take somemeasurements on the Iathe w e are plan-

ning on using before w e start.The other alternative is to devise am ounting for the fram e so that the cut-ting wheel can be on the far side (fromthe operator) of the wheel to be cut. Thatw ill reverse the direction of rotation ofthe wheel and the pulley can then be ontop.

,.. . ,y ,k : ,, j ..h ''.1 j.

sary. You could use som e drill rod (silver '. wings . w e need another 0.125 inches face pla'te and are parallel to the face. drateed) to make the spindle itself so that it oo ' . f material beyond these pieces to hold glate.

is good and stiff but you do not really : 1 0 i s gives us a bar width of 1 .250 BOLl9hlY estim ate the centre Iocationem . Th' 11 that Iong and slender - - - - Y - p t ofthefaceplateanddrilltw oholesintheeed to Itsnota jaes

7/23/2019 27 - Spindles


g p t oteacepatea ddtw ooesteeedto . It s not a . jaes .. inc fkxture to allow you 'to m ount it to then any case, and the Ioads imposed by oo 1 . . . Mark and drill the two bolt down holes bar

cutting sm all brass gears are quite sm all. one end of the bar These are 10-32 face Plate. Centre the centre button at

, on jt tjae bar fixture tightrepare 4 pieces of the bar as follow s: ::A) clear holes that are to be drilled 'Uk Iathe Centre and boFuure 2.a Top: basic gear cutr/ng frame ( to the face plate .on ballbeanhgs. ioch in from the ends of the bar. Deburr

* 2 pieces 2.000 inches Iong for the , , , d file the surface down after drilling. Rem ove the centring button and drill aanop and bottom. , ' u ark the centre of the face of the bar Centre drill in the part. Drill through Fk

@ 1 piece 1 .500 inches Iong for the large face. Study the drawings. 'J mark the same distance (0.500 inch. Open out to /2 inch with a drill and anvertical back mem ber. The trick is going to be to m ake both j pches) in from one side. This will be the bore 1he hole out to about 0.750 inches.. 1 piece 2.500 inches long for the yarts identical. The most important thinq entre of the bearings . ln the drill press A1 this point check that the hole is actu-

cool holder tang . M ake the tang Iast Is that the threaded hole that accepts the drill a No 34 hole at this point and tap it aIIY Centred on the three sides of the bar.so that you can fit the mounting that bearings be centred on one end of the 6 - 32 (4BA). M ount a centring button to lf not, nOW is the time to m ake a correc-you decide on for your particular ap- parts and be exactly at right angles to the this hole and fix it thatthis bulton is equi- tion bv repositioning on the face plate.plication. face of the part. This can be guaranteed djstant from aIl three sides .

This can also W hen everything is aII right, open the holeby m ounting the plates on a face plate be done by m achining a disk 1 .

000 inch OUt to 0.800 inches diam eter. Thread theThe first two pieces, the top and bot- and cutting 'the lhreads in the lathe. jn diameter and 0

.375 inches thick and bole SO that #ou have threads that are

tom are identical. Start by m aking the The bearings that we are planning to usinc this to centre the nart in the Iathe 0.876 by 24 tpi. These will have a theo-parts exactly 2.000 inches Iong. Make use have an inside diam eter of 0.250 (on Whe face plate)

' retical internal diam eter of 0.832 inches.sure 'that 1he ends are at righl angles to inches, an outside diam eter of 0 . 625 lt is easier to cut the threads inside this Tbe exact diameter is not critical, it isthe face and sides of the part. File aII inches and a thickness of 0.1 90 inches . pjate on a face plate because the face more important to get the toq pla'te andim perfections so that alI 6 sides of each These w ill be held in threaded pieces that pjate makes it easy to m ount the part tbO bottom plate as close to Identical aspart are flat and at right angles to one need to be 0 . 375 inches greater in diam- parallel to the cutting face in a Iathe . POSSible.

another. eter than the bearing OD with 24 tpi Make a bolt down jig from a piece of % Vachine the other plate to be as identi-Put m arking blue on each part on one threads on the outside diam eter. See inch sq bar stock . Drill and tap two holes Cal tO this plate as you possibly can..o match the holes in the bar and bolt the

., d sack of frame ' ' , . . j 12s inc: frame bar dow n to this fixture, good an0.250 inch ' o

.62s inc: .. . . ) tight. check 'to m ake sure that the parts The back of the fram e is m ade of the

. : jt ' fit together and that they sit flat on the sam e m aterials as the top and bottom .,

,..

js 1 soo inches Iong. special attention0.250 inch . , . . *. . S . j tjg yo j;a gjsau yo makjyw yjqa ayyyjg ujî S: CCC

j j . ; j jyj gsgjsy jo yjja jaoyoyy. 0.7s0 inch - - -1 - - - 1 . 2so inch ..'' '. '. 4r ' '. the part at r g' . I .I , )î. . ,. . faces. This is much more critical than thejy. , g , ., . ' - $ y; ' Iength of the part. After you have

( , :wo holes I I Thread 1 125 by 24 tpi in Iathe , ( . o , .. '... ' bottom to the back and check that the10 32 clear #11 I ''t '' ''' ' % '. : assem bly is square and parallel. lf neces-. . '

l 0.500 inch I * -. .''' sary , adjust the f aces with a f iIe or by . ' . I l ,;I . t re-m achining. The top and bottom plates

$ r ' , ., need tO bo jarallel and square so that the. . ' i i '' ' 'I'WO OF THESE PLATES : bearinos WI1I run properly in them. Lay2.000 inch ARF NEEDED. ''' the assem bly on its Side to m ake Sure

;. ,r, , i,; ., ; .à,. ,. ,. Fiqure 1 2 .

s setup sr threadtàg top and 'tbat it Iies flat.'

Figufe 12.4 Top andbottom plates. . :olro?yl pfates in yar/?e (on face plate) . q.( '' Clam p one end plate accurately to the. h . . ,

' .,(,) ;', j . .

94 ' 95 '''

$ '

Once you have a nice f it on thew 1.500 inch 0.500 inch threads, take a very f i ne f inishing cut on

tjya jace of tjje p a rt, cjna m f er the l ast

orillandtap10:2 ' threadsoneaclaend.M akearecess

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orillandtap 10.:,2 . - - - - - . - - threads on eacla end. M ake a recess.ourplaces. -- - -- o.z

-soinc: a. o.oao incines deep and tlae diameter of. . j. t. 1 .250 inch () 75o inch I bearing should be a snug f it in the recess

. ' j .. . . . . . . . g . . yp x yssyyyss gye yejy y pjgce. C i) 3 mf r aI I edg es .

j Figure 12.8 part off a section O . 2 1 8 inches thick.eaded cups hold the Ofll6'f races 0/7 DlaceThe (ocation of this recess for Ihr M ake one more part identical to this one.the mounting tang is to be /?? the frame. qepeat the process f or the other end0.062 inch ::::::: a determiflcd ffom yotlr tOOI post

- - d lathe centerheightdimen- plate and make two more threaded cupsn.. , . .' . ., sions. sweat tang to tuis recess. iraches in diameter. Hold in the 3-jaw for it.

k Face the end and centre drill the Next we need to cut w rench slots intoFigure 12.6 Backplate. CbUC 'iece. Drill into the part 1 .500 inches these tw o sets of tw o parts. At the least

,y incj.j slot across the back ofeep w ith a 0 . 250 ioch drill. Open this we need an aback plate and spot the holes through bIy that will not slip on the bolts . out with a 0.600 inch dril and bore this the parts to allow us to tighten them intointo the back. Drill and tap these holes cut to 0.562 inches. the threaded bearing hole - four or six1 0-32 (2BA) at least Fi inch deep. Bearing support rings The bearing seat has to be the diam - would be better. The slots should beBepeat on the other side. The bearing support rinns thread into the eter of the bearings and 0.080 inch deep. 0. 1 25 inches wide and 0. 109 inches

Now using Loctite between the parts threads that were cut CIn the upper and The bearing should be a push-fit into the deep. At this depth the slots will justbu1 not on the threads (and this takes low er plate just described. lf 1he lhread recess bored and a little less lhan half the barety miss the bearing recesses. Debufrsome care so use very Iittle adhesive) diameters are not identical in the above bearing (0.01 6 inch Iess) should go into hole, slots, threads and the recess aII theassem ble the two ends onto the back parts , you w ill have to m ake two differ- the recess. This w ill Ieave 0.032 inches w ay around.and Iay the assem bly of a flat surface on ent sets of bearing supports , one set for between the caps when tight on the Place a bearing between the two parts

its side. M ake sure it Iies flat. M ake sure each of the plates . bearing . and thread the assem bly into theaII com ponents are vertical and tighten Start w ith a piece of free m achining Thread 1 500 inches of the outside of threaded hole in the bar that fits these1he screw s dow n good and tight. Once steel 3 . 000 înches long and 1 .062 the bar to 1 .00Q inch by 24 tpi. The threads. Tighten dow n w ith a piece of 1/Bthe Loctite sets you w ill have an assem - threads are cut to be a snug fit on the inch plate m ade into a special wrench

, t . .'' . ';s .' ',è '', ' Iarger of the two end plates that we just for this purpose. See drawing. The

0.13: inch 0.c80 inch made. W hen cutting fine thread and try- bearing should feelright at hom e in itsI 1.000 X 24 TPI to match ing for snug fits, the follow ing points housing. It can be moved up and down

the threads in the top and i ind : by threading the assem bly up and down (j to be kept n mee. -- - j - .- . bottom plates

' è '.t. ,::,rc,' , . . - - : : - . . and then re-tightening it. At 24 tpi, each. : l : .. () :as jnch dia d f ree of turn of the assem bly moves the bearing

.. ' ' ' . ' @ Keep the w ork clean an0 562 z '. match bearing

Bearing ,' ' .. burrs. 0.041 7 inches or about 0.0 1 0 inches f r

inc: .- - - - - - iameter - : - - -1 - - - : - - . Keep the thfead bottoms clean. every quarter turn. Fairly accurate adjust-

tight (0.625) ', l ' . yake very sm all cuts or YObI W ill have m ents can be achieved .# ..

4 I . 0 .

562 inch dia t bef re yo u knO W it . . . over-cu. u '-

- : j : . .- - * w ork at slow speeds. The spindle shaft

:.y'

2.- - . . . . . z. - '' . use very sharp threading tools. I will discuss tw o w ays of building up the

:?:r,. 0.12s inch I 1 ., ,, k ,, . o ,zs inc: I , Use a thread gauge to position the shaft (and describe one). one scheme' , . ; slot ë L . . w'ide slot ' o jas in slot on other

.'? t

ohreading toolaccurately. has the pulley between the bearings and

' '- forspanner ideorwrenc: o not forget to round off the thread the other has the pulley above the bear-. .' ,.; 0.218 inch s

CrOWnS before YotI test Yotlr f its . ings . 1 think the iatter is preferable forFigure 1 2.7 Clamping rings - four rings are required. most users because the belt is then

9 6 î 9 7..7

.

.., , : o coo ;a..u . nrlto it and the belt. Also consider that it Take a good Iook at the drawings

hs ' ,, : w.uwu 'uwu, , :j. drjve a pulley that is m ounted Start with the section of the spindle that . .

. ; ,.,,: js harder to. ? .

' near the Iathe bed. In either case, we goes under the cutter. Cut off a 0 . 500;7 ' . , ' . i . ' IoW

.'

,(. 1. ' : .2h. '' ould have to uSe Sm all belts to drive the inch piece of silver steel 1 000 inch Iong.$ tv406inch '' ' '

7/23/2019 27 - Spindles


g $ tv 406 inch,

,

m'the space available is so Holding the part in a half inch collet , face', ' Qck dim ? ' ' . .

' $ ,yi) ckltter because . . . ()

2y., 'r jjmited. the Part and form a boss 0.090 inchesrop bearing clam ping . (, . ja djstance Iong and 0 . 250 inches in diameter on the' 'S''. ''' ' Iocation. centerof top .''.. . .. It is desirable that t e. isgs of the frame be as end. This should be a snugfit in the Iowerlate. . between the bearvap jtl-w .: ' L .. 1. ':7 mall as possible to give us a shaft that is bearing and just a wee bit shorter than.:r,. ; k) r s

a , ; s stiff as possible. This requirement also half the thickness of the bearing so that, g' y j 1 . 0 i C OY yj S je ti rn ajyydytjheo ej o b yjtj j i ' ' 7 r d u e s t S p a C e a V a i l a b I e f o r t p u l I e , w e c a n c I a m p i t o t h e i n n e r r a c e . N e x t,' )... . ;) depending on cuttersize. so even though every design I have seen drill a centre in the end and then drill a No

. jaces the pulley between 1 1 hole 5/a inch deep into the part . Care-, .e ..- in the Iiterature pj i s I am going to suggest that fully tap this 1 0-32 (2BA). About 0.375''ï .. ,t' , ) . o eej cutter aamping . tbe boar nf ,' ; better location is outboard of the inches of good threads are needed .r7, . Iocation, Center in the frame ' . the, t , ksarings, on top of the fram e and that is Turn the part around in the collet and

,. . , . kon

. face it. place a very sm all centre on this '6:' -; . . ; ' the W aY I W ill describe the çonstruct%

.X . j Let us assum e that the largest w heel to end. Rem ove and m easure the Iength -

.E' ' ' ;.000 inch . , be cut w ith the Spindle W ill be 9.000 the theoretical finished Iength needs toJ.k'' j yao 10-32 .' ' ' '2.' inches in diameter (aS in one of Mr. be

. t O v ,. w ilding's elegant skeleton clocks and:,, j;s tjorje oj.y 1 .000 jnch - (half the bearing thick-' Bottqm bearing clamping ' ' Qbotlt the lim it of w hat can - -s. .a .n.t tjje cutter ROSSI - (half the cutter thicknessl

: Iocatlon. Center of bottom the Myford buper / ) anq Ina. plate. we use w ill be a standard Thornton cut- Confirm the Iength for your fram e . Once406 inch? ' '

. . check dim ter 1 .000 inch in diam eter w ith a 7m m the Iength is right, turn a stub dow n to

, hole through the centre. W e will design 7mm in diameter and the thickness of thelear the above dimen- cutter minus 0 . 01 0 inches. M ake sure. the m ountings to c,

' ' '

n soc in. pulleytq suityourcuuer .. , sions. that the step near the yz inch diam eter is. 1.l .

' and drivlng tackle. . There is also a problem W ith cutting absolutely clean so that the cutter w ill.' . '' '

, extrem ely sm all w heels and pinions but I not hang up at this point. It m ust seat .. I: g . ' . have found that those are best cut w ith a perfectly. Check the diam eter w ith the. . Figure 12.9 verticalsection across swww/eparrs . horizontal spindle Iike the basic spindle in cutter that you intend to use. The stub

chapter a . needs to fit inside the cutter and there..

, ,46

,

'.

'

Ajj jjle work of making the spindle should be no play - this is a critical f t.easier to remove. Also the belt and pulley but the sm allest pulleys will interfere Ports w ill be done in collets. l recom mend Centre drill and drlll and tap 6-32 (4BA).do not get in the w ay of the cutting w ith their ability to reach the w heel to be that aII spindle parts be m ade of silver Carefully cham fer aII edges and polishoperation as m uch as they do otherwise. cut Placing the pulley outside the frame Steel (drill rod). This w ill give a Iittle aII surfaces. W ipe with oily c10th and set

The basic design is of a shaft that is allow s us to use a Iarger pulley and to Qdded stiffness and w e need every bit aside. This section is now done.

built in two sections w ith the cutter have m ore space to m ounting and driving that we can get on a sm all spindle. How- The upper section of the spindle isclam ped between the two sections. Each the spindle . ever, silver steel is hard to thread and it is identical.section is then supported at its other end Let us take a bit m ore tim e to consider Dot essential that it be used. Take a 6-32 cap screw w ith a Iongby one of the two ball bearings. The pul- a pulley betw een the bearings . If we First take a 1 2.000 inch section of threaded section and salvage the thread-Iey can be placed on either half of the m ount it on the upper half of the shaft ,

it 0.500 inch silver steel and polish it so ed section from it. A Iong set screw canshaft or outboard of the bearinqs. The w ill interfere w ith our abiliw f'n nmn w hat that aII blemishes, rust and dents on it are also be used. Screw this into one of them ain problem is that the cutters used in is going on . If we m ount it on the Iow er rem oved. This w ill allow the parts to be spindle halves and place the cutter on the

Iock making are rather sm all and thus aII half of the shaft,

the sw arf will fall dow n h6ld in the collets with greater accuracy. stub. Screw the other half of the spindle

98 . ' 99 .. ;t ,'

onto the screw. The cutter should be held Final assembly Everything is now in place. Notes on using the frameFirst do a dry run trial assembly to maku Tijhten the two clamps on the Iower The frame can be mounted either in a tool perfectly.

h Iathe . 80th halves of the spin- sure that everything will work the wa> bearlng and tighten the cap screw on the holder for a quick change system orun t edle and the cutter should now run true. lf you think it is going to. This is your last bottom of the spindle in the pulley. Every- bolted dow n w lth packings as would be

7/23/2019 27 - Spindles


not, we need to find out what is wrong chance to make adjustments. thing on top needs to be Ioose at this time done if one did not have a quick changeand fix it before we go any further. Clean and prepare the parts for finaj but the spindle will be constrained by the system . It w ould also be possible to use a

Unscrew the tw o halves of the spindle assem bly. upper bearing. The bearing should be Iarger m ounting tang with a hole in it soand put the bottom half of the spindle M ount the mounting tang to the back joose up and down. M ake sure it is and that the assem bly could be bolted downand the cutter away for now. of the frame. Use Loctite on the threads then tighten the upper cap screw so that on the tool-post stud itself .

Using sim ilar screw and register tech- and at the mating parts. Using Loctite on the spindle, upper bearing and pulley are The spindle can be run at betw eenniques m ake the top bearing clam p. the m ating parts gives you strength one. Once this is done, there should be no 2000 and 3000 rpm , for brass, w ith

against twisting of the joint. Thisjoint can radial play in the system but there might ease. Use a discarded washing machine.

., . , g.pulley . i' . . ..' . . be welded but there is a danger of warp- be some axial play. or similar utility motor (for further infor-M ake the pulley on a piece of free ing

. The axial play is 'taken up bv moving the malion see Electric Motors. W orkshopmaclaining steel stock 1 zso inclaes in di- Next mount the toq and bottom plates Iower clam of the upper bearing up until practice series No 16 and ElectricMotorsameter and 1 .000 inch Iong. Hold the to the back. Here agaln use Loctite on the the play just disappears. Then tighten lh the Hom e Workshop' W orkshop Prac-art in the a-jaw and take a cut to true threads and at the mating parts Before everything dow n w ith the upper clam . tice Series No 24, both by Jim Cox andp

the diameter. Face the part and centre you tighten the parts dow n, Iay the In the final analysis , the spindle should published by Nexus SpecialInterests).drill it orill a 1o-a2 clear hole through assem bly on its side on a flat surface to run freely w ithout either play or binding. The spindle needs no m ore than about 4the part. Turn the bearing register and a make sure that it Iies flat. W hen in use the bearings should not get hp for most applications.0.500 inch diameter section to clear the Allow the adhesive in this frame hot. There should be no compromise as The cutter should be at exact lathefram e . The pulley section will be ?/2 inch assem bly to set. W ipe away aII excess regards the proper and precise rotation of centre height for w heel cutting. The spin-thick and w ill have a pulley groove to adhesive and m ake absolutely sure that the cutter . dIe should be qerfectly vertical. Thematch the belting that you intend to use.there isne setup should be rlgid. Lock aII slides that

Turn the part around and hold it in the the bearings. Clean and lightly oiI the ''' ' :.. ' ' are not to be moved,x inch collet . Face tlae part to make the reces' threads. Loctite will set up in fairly , , . Most gear cutting for wheel cuttingeltsection exactly x inch Iong Machine oily parts, be careful. , . .' .. ' should be done in one pass for eachthe groove to the dim epsions of your Assem ble the two halves of the spindle . ' ', ' ''' . '.'':;'$ '.k 't; '' t00th. . ),. . , .

choice. Bore out the m outh of the hole in and the cutter. Place the tw o clam ps thatthe pulley to accept the head of a 1 0-32 hold the Iower bearing on the Iow er bear- r , '' '

. . , ., ) q .

(2BA) socket head cap screw com- ing and thread aII three into the Iower . , ' .. ', ....... ;. '

l I Cham fer aII edges and polish with plate on the fram e. Do not tighten any- ' 1 ete y.emery papers. thing .''' '. ' ., ., , , . ,, t ,. ,y.

Drill and ream a ?/:e inch cross hole at Place the Iower half of the upper clamp . ', ' ' ' ) '.f '' . .. . . the centre in each half of the spindle on the spindle and Iet it rest on the cut- ' .

',

'. '

r .. .. . . . ... . .shaft for a tommy bar. Chamfer both ter. Place the lower boss of the sqindle in . . ... . . . . '''sides of each hole just slightly. Make two the Iower bearing and bolt the splndle to . ' 'i '3.000 inch Iong tomm y bars out of 3/1s the Iow er bearing w ith the pulley. ' ' . , . ,. ' . , t'/ ....... . . . . . .. . . . . . . ..inch ground silver steel (drill rod) . Now thread the Iower clam for the : . : ., . .. .Do a test assem bly with aII com po- upper bearing into the upper plate until it ' , ' ' '' . . . Jt, . . ,. j , .. ;, , , 3 ; ' .; ( 4 ($ . . '.nents and the upper and Iower bearings is not quite flush with the bottom. Place :4y ,. :'''j , .) , : . ) ,., ? . . , . . , tto make sure that everything assembles the upper bearing from above and threa : , ,, r; , ,.,.up correctly. Nothing loose, nothing the upper clam onto it. ,,., . , . ,. 2

'

tight, Everything Iines up and runs true, if Place the bearing clam p on top of thenot, fix i1. assembly and put the cap screw dow n ?; . .: , . . . .h, , , . .

' ' . î : rtf .

into the spindle. Do not tighten yet. - . - -. , t . .' , . .'

1OO 1O1

,'

, . , , , .. . , . .. . yy.... ..,, . jqfliLiliilqîjijqvkkyljyjty.y vjaese are b0th valid observations andE j ., , ,,, ,, ( , . ,, . ., ,. ., yyjy . y y) lqvqyjj yyyyjyyyyyyy . s Njjjs spjyytjs js kj-yojyjqjojj yo yjojjy-jo yjya

7/23/2019 27 - Spindles


j .. ' , ; . , t , , k . ,. .' , ,.. . .

. ',

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jj j -l j jji j:jjja jgi j jjj j-l . j:y;j lkpjjr j, j(jj je j j:;j jj j gj j, jjj jj . j ijjj ty .)jjjj jjjjk.(). I .. . t . .?. :. .. '

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.. jj. ,,LL'L.kIIq,y)., : g y j ( j,jy y ys. jy. , .. < ' , ' ' ) y ?j y: yy() yytyj t jyjy y j jyjyjj yjy yyy jyy yyjyy jsyyyyy yy.j j yj )j yz. + j.y j tj j j.y o j.a a , a yjy s j s s g j.j o y jj.j u s q j s tj j a. . . ..,. . , ... ' t#.:.-r.. )-. ?j. ; j.. y., .;. .. .- -.- - . .'- .. .. .. .-, . . , , ,(: ))l k .,,y

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Y ' ' ' . ' .$ '' ' ''' TW Q //J Ch JY'. Y fTlfnl Y/9/Xd IXC SNIY Y/C WXh W 11 O U t 1 Z b i 1 i tY 10 m O U l'1 t C h U C Q S a n df Fl . . . , droger Nearags

. This ,z. the smaqest face plates as show n above. Note that, . ; tapere'' ' ; ' '' taper bearing spindle that can accommodate this m oves the M orse taper in and de-

, . ' , . ) . . '. the spindle ntMe of the M yforl S7. Creases the amount of m etal between' ' ',. . , ' the inside race of the front bearing and

lntroduction . tance between the bearings and thus the Morse taper. This is not critical but. I increases the rigidity of the spindle as M aking this spindle housing 2.260 w ould not be acceplable in an induslrialThis is the most sophisticated design in determined by the bearing span. inches in diameter instead of the 2 000 spindle. Figure 1 3.2 is included only tothe book. lt uses heavy duty tapered I should mention that this spindle is a inches shown will allow you to use the show you what can be done. The spindlebearings and separate seals. It is also the Iittle harder and m ore tim e consum ing to clam shell m ounting plates that w ere is not described in detail but can be builtmost rugged of aII the designs. I do not make than any of the rest of the spindles made in Chapter 4 for mounting this by follow ing the instructions and chang-think you need to make a such a heavy in the book. I was not totally satisfied spindle ing the dim ensions as needed.duty spindle for your day-to-day am ateur with the fact that the front bearing is so using taper roller bearings m akes thisengineering needs. far back into the housing. This was the a substantial spindle and som e amateur Bearings selected .

Tlais spindle could be m ade Pi inch (or best com promise I could com e up with engineers w ill consider it to be overkill

more) longer and w inch more in diameter and s'till s'tav within 1he 2.000 inch diam- for the Myford Super 7B. There will be Quantity 2to m ake it even m ore heavy duty . eter spindle housing, and use automotive others w ho think I should have selected Inside diam eter 0 .750 in (20m m )lncreasing the length increases the dis- taper bearings lfor ease of procurement) this as the basic design in the book. Outside diameter 1 .750 in (45mm ). . . . --

. 4,250 in housing Iength ' ' 4 250 in housing length . .

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Standard M/ord Super 7 nose '' ' ' . . . .... I L .' 2 000 ich diameter 2 000 inch diameter .. . .

Figure 1 3.1 Section across spindle with taper bearings. Note that the need for seals Figure 1 3 . 2 Sectlon across spindle wlth taper beanbgs. Bulldlhg ?r wlthout them oves the front beanbg farther inboard /?? thlà deslgn. ; ' chuck reglàter shortens splhdle .' . '

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gJ: y jE.. :. .) qE:.tt@ :t t C j y y y:E r j ',j.),E: y Ej jyjy y(j y,s a1s 80th sldes ' ' '''' ' 'ï' ?.ks . ,:)t,...' shape by boldpng 'the part accurately - - ?zfrîJ#(z:-?:,-:)lèi?i,'Eïttz.è.ktt,i.. 7.L'',:$.t)t)rt,:,ttEtttj,@il . . . j . . . jyyjj 'm' ::( jj j'( ,j y,g:j: ..j,, . ; p k j... i .E) g.. )) ) ..j ) ';y' .j'L.t ).g.j y jy. .: j gjj)4y>#rltr::;:; between the 4Haw and a baI I beari ng 7IIVV) '' : ' ' ' '' C ' ' ' ' t: fj J: ) . . . . . ) . . #gt./ EE ( y qygjy këpjyé , . . p# 1 ? ) j: àj .. . 'yrijrjyrg; ) ? . j-ja taijstock . A lot of rnaterial îXj.12Z1':: 'itliltriheals selected .. - centre In t j jy/ ) k'atljyyttj

7/23/2019 27 - Spindles


jjy .) ka tljyyttj

Inside diarneter 1 .000 in (2 srnn'1l , , ):?ïi)#E, Cgy ,, , , . thls phase of the w ork just to get the E. Ey ltjyjytj yjyyyyyyyry.syyu,tyjyy yrE.-ugy. jj -g,xy,? yj rj ,, ,.s;y yyy ,yyytyyjy ., y () j:y,y, 2 ya ,.. ,..jj,. ., . j.j j jj gj jgy j;j r j, ?l () yy yj yyj jjsj jy: . j .yyj y y,yjyy yjyyy h af t s 1 ze ltf tL:pE j :jj.jrE:y n ose ro u g h l 9 to s ze . Ro u g y ( ègjta E j y,g?, y,t.; jjs ,?.,,- y. . y.s,,,t,,,, ,,r.y,,.j,,ylutside diarneter .. .aso in (48rr,n.') '.'.,t','.;. ïEtt.',,.,i?.?>? . rneans tlaat we Ieave at Ieast o-oso ,.., rtëiz-.,yï,,zr:.:,kt,.ttt,,.-,..:,.?t,t#-tt,ytk.ë'',,..t,ky -j:,yy);t-t,h)) (Ejtkkët,, .tjjt-tt- , ,.,- i., ,, .ë-. . . :,-, g-.$rt:,,,,-y,y:,t,y)(,t-y,y,(,j,jht:,-,ty,,j--t#,)yr,).,,,j,,tj-jàj-j: ,jtëy: ,,,,,ë y, ytyyrt,tt . , yy,,' Iç: n e s ( d:)p ,k/' e 1- ëg' I I ) 4::, . :51r4::h ' ' ;è' '' t'C L'''', '' : ..' -, .-'''' - - I-, e , ; o I-,l 1g :l e , ; a 4:11 4::, . -1 d::h 4:2, 1 n 4:, l-?d e s d:)p n ''.i ..Ff .t .-$:-....- -.. ,.--.' - ,.. .- , ? ., . -.a, --..'..- -.-... ..'-,- .... - ,-. -.;-.; , .. ..'. '.:. .ti2r $-? ;'h . ' .. ...-l- -1 I w ;)tr .. u. . 1rll )t ) '' ' yk ' . . . . . .L dlam eters on each crltlcal dlm enslon for Taperedbearmg spindle andpullev s/low/y?s

Materials needed ' ' . ' (t$ : final f inishing . the pollbhed Seal S&?-/'fOS needed On the:;j ; jtjfy yaye sjtatt and the tv/w'/?s pg//ey .M ake'' 'V' ,trt.

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,j jj, .jj : jr, j ,. j.j) :gy .kr., k ;.jj.k$2:, jj . j kE ,,:yj .ky.y yjyj;: jjjtjj rj;, j::jj, . ;j;. ;,;jjjgj j.. rg;y . ; j :yj,j; . ,rg ; , , j;, ;:r ,.j ..j -jgyj; jj.jg jj:jj . j j.-j,,y lgjij;,,k 2gy.,. ;j,r,,j;.jjt g;,j, jg::ijj. ,jkyr jt::yjj:; ,kjj- g:rj,j,.j j;j jjj,jj,,j;:)j r, j,:r j::y ijjjjy, kgjy ..H ou s n g 2 . w0O i n 4 . ..w w in ' :. )k:è.E( y'ttj:Eâ$/yEE) g:( t jtj sjj E 4rry::h: r:jp:): rjyy . j m j g jjt j. ave s h 1 f ted s o f a c e f ully to m a ke s u re th at the m a c h - ned ) .y jjg y y y g ..t g. . j.j m ajgrj a 5 0m m ) ( 1 1 5 mm ) T O .pulley 2.ooo in 1 .1 26 in lnternalsmhdle assemblv o/ taperedbearing the end again to make sure that you have nose is actually suitable for making the

(5Qmm) l30mm) spindle showing relative bearing and seal a 'true surface. Bore a slight 6o-degree finished spindle. If not, now is the lim e tosut. 0.760 x 1 6 tpi , 2o x 1 asmm placem ents on the shaft A wide :ear/kw recess in the end of the hole to allow the start over before you have done a Iot ofwsee Appendix 2 for UK equivalent placementl's demkable forstiffness. spindle to continue to accept the centre finishing w ork.

. . .accurately. Replace the centre. lnstructlons for m achlnlng the spindle. . . . . . . - 'Flrst purchase the bearlngs and the seals. * Open thls out to 1/2 Inch In dlam eter nose threads are glven ln Chapter 3 on

The seals selected should have the sam e as far as it w ill go. Note the 2.250 inch diam eter spindle.or a slightly Iarger outside diam eter than @ Support end with a ball bearing cen- If using M yford chucks on these high- Once you have the registers andthe bearings. Their inside or sealing diam - tre. speed spindles it is w ell to rem em ber that threads right, m ount the two face plateseter should be 0.250 inches Iarger than * M achine M yford 57 spindle nose on cast iron chuck bodies have a finite rota- on the Iathe spindle. M ount and centrethe ID of the bearings. W e will make the end. tional speed before they burst. spindle on the second face plate as

. . .parts to fIt the bearlngs and the seals. * Reverse and re-centre uslng tw oFoltow ing a logical sequence the parts face plates 0.25(r ' '' ' ', . h'. ' , .Wi I I be f a bricated 1 n the f ol Iow i ng order : * Face and d rill a I arge centre . o soo.. o soo'' '3Z5'' ' 0 .437.'

* D r I I h o I e 3/8 1 n c h 1 n d 1 a m e e r t o m e e t ' I

g syjjjytjja s j .. .. j. . .,.s,. .,.,. jjojs jyom otjjer s'de . . . , .. u . . C . . . Maln IIOUSIng . . .'' ' C ' @ W OFk betWeen Centre and reversed Overall Iength =6.688 inches .' '

. . . ' Key recess3. Drlvlng pulley. ' face plate.4 Nut for driving pulley. ' '' * M achine rest of spindle.5 Flnal assem bly. . ' . . ' #2 Morse Taper. . . . .'' ' ' The splndle w lll be m achlned out of a ' - - - - - - - - - -0.375inch hole- - - - - - - - - - - - - - -

1 . Snindle niece of m aterial 1 . 7 50 inches in diam - *

.. - -he sequence for machining 'the spindle eter and 6.7 50 inches Iong. We will not . . . . . . .is as f ollow s : ' machine the spindle No 2 M T at this tim e l ooo inch diameter ' ''' : . o 7so'' diameter sttaft '. .. .

- that w lll be done as one of the last tighton bearings* Centre the blank in the 4-jaw. operations when we f inish 1he spindle in 1.750 inch diameter .. Face and drill a large centre . situ in the bearings. 1 zsc iochdiameter .. . '''. orill hole x inch in diameter as far as The initial work will be done between 1.125* by 12 tpi ' , ' - '

it w ill go . the 4-jaw and the tailstock centre . W e . ? .. '. .. '; ' Figure 1 3.3 Spindle dimensions. ''J' ......rj :4. p,( , 1 05

E'''

.

described in chapter 3. Remember that back bearing seat at one time because if . ' . ' ' ' .'.' i there is any taper in your tailstock setup 4.250 inchesoverallhe centring has to be perfect at t ,

stage. you will get one seating Iooser than theNowwehavetopolishtoahighmirrorotherthedangerbeingthatyouwill

7/23/2019 27 - Spindles


Now we have to polish, to a high mirror other, the danger being that you will .

finish, the . 'ont of the spindle that is going to be o.2so by 28 'under the oiI tpi oiI plugbright, w e will shorten the life of the seaà. bearing, then prepare 1he sealing for the 2.(1* .

between the '' '' ' 1.500 ine, inchurfaces can be brought to a higb finish front bearing. The space jmjetjjj.u diameterby applying successive grades of emery two seats does not need to be a tight fit .. 'paper to tbem w ith a drop of oib. start but should not be too Ioose because w e '

finally do not want to remove any m ore m aterial 'w ith 220 grit, then 400 grit and6oo grit and even 1 2oo grit. spin the than we have to. The pulley has to be a ''work at 1 ooo rpm and clean up between tight fit because it forms an oiI seal in this Recessestomalchthe bearings anu seaks purchaseu ' .

'

grades of paper so that no Iarge grains design. This means that the front bearing '

remain to spoil thework as . ' swre 1a.4 Housl'iw tsra/ys. ' ' ' ',' 'to finer andfner to get to its seat. Remember - the seat- ' 'Now work between a face plate and ing has to be tight at each bearing but

the bajl bearing centre aswe did wîth the can be loose in between bearings. This ca1 - each end holds the outer race of one face to work wi'th so that we can centrebasic spindle. Face and centre the other means you have to know w here the bear- bearing and one seal. Once the races are the spindle accurately w hen the need11 fit in the finished spindle . fitted they do no't need to be removed. arises.nd of the spindle. Drill a b inch hole ings actua ythrough it to m ee't 1he hole from the other Once you are happy w ith the seating of However, Sf you get them halfway in and The bearings and the seals m ay not be

side . Make sure that the centre is perfect the bearings, it is time to cut the threads jam them in there, it is a mess because the same size: it is best to bore the seatsafter the drilling (fix it if it is not) and for the nut that holds the pulley and inner they will be very hard to get them out. for the seals first and then bore for thebring the tailstock centre up to the part. races in place. These threads should be W e need to work hard to keep that from bearings because there is a possibility

Again rough machine the outline of the cut to m atch the purchased nut. The happening. that we will disturb the bearing borespindle first. threads are to extend o.1 25 inches undef 1 w ill describe 'the w ork needed to be w hile we are m aking the seal seating. By

we will start the finish work by the pulley (this 0.125 inches includes the done for one side and then the same getting the seal work done and out ofmachining the seats for the front seal, recess to clearing the threading tool). effort is to be repeated on the other side the way we can then bore for the bear-then for the bearing inner races w e are once you have a nice set of threads after 'the part has been turned around in ings and be assured that we will not dis-aiming for a firm to tight push-fit for the cut, chamfer on aII edges, and clean up the 4-jaw and sized to a 4.250 inch turb our work. The rule is to always dobearing inner races. This is the hardest the work. length. the most critical part Iast, even thoujhpart of making this spindle. The portion This completes aII the work on the out- Hold the housing blank in the 4-jaw that is the worst time to make a mls-of the shaft betw een the bearings can be side of the spindle except for cutting the and centre it to run true at both ends. take.turned dow n just a bit to allow the front keyway. The No 2 MT still has to be cut. Face the end and drill a centre in it. I am not giving specific dimensions forbearing to slide over to its seating after it Pass a file over the housing to clean these recesses because the chances arehas been slid over the back seating. 2. Main housing uq aII the bumps and blemishes.Polish that the bearing and seals will not be the

First we have to machine the back of The blank for the main housing is a piece W1th em ery clo'th - this should give you exact size that l have specified, so make

the register flange and the back of the of free m achining steel 2.000 inches in a nice finish. If the finish is not to your the recesses to suit. If the seal and theseat for the front seal. Once the flange diameter and 4.375 inches Iong. This is Satisfaction, consider taking a very bearing have the same OD, the recessand seal sea't are right w e can proceed 'to be finished to 4.250 inches dong. If hol- Slight cut with a round nosed turning has to be sized for 1he bearing and thewith the rest of the spindle. Iow bar with a 1 .000 inch hole in it can be tool to clean up the bar to suit, but avoid seal will conform to the recess. Use a

. '.. . obtained this will save a Iot of work. If doing this if you can. (Keep in mind that carriage stop to make sure that you docaution not, we will have to make the bar hollow We need to hold this in the clams so we not overbore the seal and/or bearing80th bearings have the same inside diam- (not a trivial matter on a small Iathe) Cannot take too much off.) Then polish it recesses.ter . Do not try to cut both the front and The two ends of the housing are identi- up. W e w ant an accurate, polished sur- Before you rem ove the housing from

. .1O6 107

.

. sthe chuck, alw ays cham fer aII edges and Instructions for turning the pulley and sare that the seals seal and clear the Now slow ly tighten the nut onto thepolish up. cutting the keyway are given in Chapter rotating surfaces properly. pulley as you rotate the spindle by hand.

Once you are happy with one side of 3. Please refer to those instructions to ' A point will come when it will no Iongerthe housing, turn the housing over, turn finish the pulley. 5. Final assembly be possible the rotate the nut by hand.hIhl42ihd Likhhdi llib il blkl Ahiil'Piihdill

7/23/2019 27 - Spindles


g g py y pythe Iength to exactly 4.2so inches and Like the taper, the drive pulley is best ginal assembly takes place once we are At this point place a 'Pi inch rod in a colletmake the recess on the other side. machined in the spindle bearings - please ''-re that we will not want to take the and place it in the spindle nose. Tighten

refer to the instructions in chapter a. spindle apart again, before the M orse ta- the collet dow n. placethe half inch rod ino iving pulley

. er is reamed and the pulley groove is the a-jaw in the lathe and bring the. rThe blank for the driving pulley is a piece 4. Nut for driving pulley ' ' P d Si nce this taper is machined in tailstock w ith a centre in it to support thetlrne -of free m achining steel 2.000 inches in This nut is the same as the nut for the the bearings to be absolutely true to the other end of spindle . Lock the Iathe spin-diam eter and 1 .000 inch Iong. As always basic spindle in Chapter 3. bearings , it is best if this assem bly is dle. You can now place a w rench on theit is the sam e m aterial as used to m ake See the detailed instructions for m odi- never disturbed after this operation . pulley ngt and take up the nut som eh housing . fying the nut in Chapter 3. This nut has to Clean and grease everything . more. Not m uch force is required on the eHold the blank in the 4jaw and centre have a set screw placed along one face It is Iikely that the bearing outer races wrench . Keep tightening the nut as long f o nce itccurately. Face the blank and drill a for a locking device . The reason for this is are already in place (before final assem- as the spindle does not get stif .o . soo inch hole through the blank. Bore that we need a very fine adjustment on bly). This is OK bedause it is not worth gets stiff tap the spindle back and forththis out to 0 . 750 inches to be a tight fit the nut to allow us to set the bearing the trouble to take them back out Clean w ith a plastic mallet aII the way round

on the spindle. Remem ber: the pulley has clearances to the right setting and this is aII pafts and grease them Iightly w ith a from both sides to m ake sure that every-be a tight fit because it forms an oil the easier way to do this . The set screw sem i-liquid Iithium grease - a grease thing is seated as far as it will go. Tight-o

seal in this design. should be a very short 8-32 socket head works better than an oil A sticky grease en the nut some m ore and repeat the tap-Turn the shoulder on the pulley for the set screw . Make a short brass pad (0 . 060 Iike that used in front axle bearings of a ping. Once everything has seated firm ly

seal. This is the sam e size as was turned inches Iong) to go under the set screw so car is a good choice . Ioosen the nut just enough to remove theon the front side on &he spindle. Chamfer lhat il does no1 mar 1he threads when the Since both ends of the spindle housing tightness. The slighlesl pre-load on 1heaII edges on this side and polish. The seal set screw is tightened hom e . are identical, it does not m atter which side bearings is desirable. Keep in mind thatseat has to be protected at aII tim es, any . ,', the spindle is introduced from . Place one the seals create drag on the spindle. Setblips on this surface w ill ruin the seal in a resl assem blv greased bearing inner race in the spindle , the Iock nut set screw . .hurrv. Do not use this surface to hold the The purpose of the test assem blv is to place a seal over it and seat it in the hous-pulley in a chuck or in any other device, determine that everything will actually fit ing. Place the spindle in the housing from Machlnl'g the Morse taper and theunder any circum stances without pro- together as planned . this side and the other greased bearing pullev groovetecting it. Assem ble up the spindle and m ake inner race on the spindle from the other See the detailed instructions given in

Side and press i' hom e. Place the second Chapter 3 on the basic spindle. Followt'r 2.08(1.'öia .'.. 0.375.' ().6B&' ' Seal in place. Place 1he pulley on the spin- lhose instructions. The pkllley groove

. '?' ., . . . dje and press it hom e. Place the nut on the should be m ade to match the belting you . .' .t . ' .' . . . ''. ' ' .

., '' I yo suit , ') f; . , :z spindle and take the nut up by hand . W ill be using to drive the spindle.

. . . ' l .7., . k : ' ' ' ' . '. ''' .'' ' 'l 1 ooo''dia j,. , . ,. . , . . .? , . . . J . .

. .. . . .: ) . . .... , . 2. , ...... . . . . . . .' 0.750,'dia ream .' & . , . j ( .., , e . , . :;r . r' .? '; .

. Ream 0.750 in ' '.....

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. ' ) .t 1 or to suit ' '' ' t ' ' ' '. ' ' $ '' qi t' '.' . ' '# é4 . f.i I . . . .. . . . . . .. . ... . .. .. , , . . .. .

'

. î. T E ' , .. ... , . . ' ( $ . . '. . .; :I . .l' . .. . . ' .., . ( '' , .. . .. '. r . i ' '. . . v 4 ..u . . .) . .. ,. . ,. ... ... . : ..,, .., )L... $ .,. k.. . , . :,. . ... . ..Nt ,, . . r., ( ..k ,.' j. .,.' . . .' Figure 1 3.5 Drivlhg pullev dimensions. '.', . .,' 'r k ).' ' ' ''. .; . . . . . y .'' '. ?. .

..1 o9o8

7/23/2019 27 - Spindles


..' otor SO that We can drill holes for the com plished with an overhead drive

111* ' jvot Shaft in them. These angles should arrangem ent. The reason for this is that, . . g jjsy goys tjujts jayga as tjjec about tWO inches Ionger than the the motor pu

. ' Motor 2 jameter of your motor. See Figure 14.2 speed of the spindle increase. Any pulley't jdtilTh tii titil 6000i hidi tidiffi lt

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' t . jor details. The mounting is not critical - over 6.000 inches in diam eter is difficult. .. ' . trgng to create a Way to pivol 1he to handle at close quarters on a small wo are

. ' s v . . , .l otor easily . Iathe .' m

. . ,. , ' .. . .

. Next w e need to have a way to support The overhead drive system can be sup-' '

. , , t,. .', t'

. . the pivot shaft on the cross slide. This ported either from the roof joists if theyBolt motorto base Gan be done by mounting tWO angle irons are not too far up (basement joists are

. , , , as required with short jje cross slide as shown in the f gure. just about right) or f rom the Iathe itself . ADrill 1/2* holes through bolts at these points. . to t. . ber of designs have been discussedhe angle irons at > nUmthe ends as shown ( j . gjgjj-speed grinding drive in M odel iW#X ddr from lim e 10 lim e and

, . .. .) .. . . , ; . . . .:.. ) yjje high-speed application for the spin- most of these can be used w ith the spin-' ' R dles i5 Iight grinding. In grinding, the cut dles discussed in this book w ithout diffi-

c . . . ;' sya s sya $ vo an take is dependent on two things: culty.2. .' f the m otor you have and hOW The problem w ith overhead drives is . .. the size Oy . . y, . y . , Angle iron flanges that are bolted to the base of the .. r . $' . j.j coolanl can #ou get to the Surf ace that they are quite tim e consum ing to. ; . . Ià m uc

. motor' Shoklld %G*e ofle another', ' ' .

: ' ' , , being ground. In our case the answ er to create, considering that they do not getFigure 14.2 A simple motormounting. '' ; '. 5 these questions is 'JNot very big and not used very often. On the olher hand if you

.. k.. . ' . ,y g . '. , . *) : ' very YUCII M Vhis IMCaNS We Con Of1ly are going to be Cutting a I0t Of clock' '

, k , . îf . . , .. .. . . ' . ' ,' ,' ' ' ' ' j? . grind of a little at time, sm all feeds will gears, it m ight be wellw orth your w hile

. . . r ., .. .,. . , , . , '., .y,..j ' ' ). g.jl , ) t .. $ q . .' . F :..'j,j,.. ? have to be Used at aII times . This in turn to bu i Id a n overhead drive .. .

)'., . . . . . . ; .:;. , . , ' ...'.j, jrive syslem . Tool-post grinder drives '., .. , . . : $;. , j njng a jaijja-speed drive unit We have two tool-post grinder spindles , ., ,, ; . ,) ,, , ,;. ,.. when des g

' . ' ''' ' ' we would be well advlsed to use a high- that we have to address: the OD grinder '.:, speed motor. Since w e will not be using spindle and the ID grinder spindle. TheseMotor ' ... DC m otors, it m eans that a 3500 rpm have spindle housings that are the same

z , (zaoc rpm in uKj Ac motor will most size so one arranqement can serve bothase't carriage angle . jikely be used. W e will w ant the surface spindles although the ID spindle has to be

yà :.. , ... ' . r .,à speed of 1he grinding operalion to be be- driven al a higher speed.' tWeen 4000 and 6000 feet per minute. The grinding wheel centre should be

. . ,, ,'b3:.' 3::., On a 4.000 inch diameter grinding wheel mounted at the same height as the lathe' 't ;y; , .î ,i . 1 this m eans about 5000 rpm . W e have to Spindle centre. (There will be tim es when. ..,.? Belt .' '' check the maximum speed of the wheel you will want to m ount these to the verti-'' Spindlej We use/buy to make sure that w e can cal slide. That is not being addressed

ky ..) . . ',

'q $ j Fasten the angfe iroq ' ''' spin it at this speed s af ly . S maller here . )

;.j k . .., down to thq cross sllde .. . wjjeels need to spin f asler and yOu need These relationships are shown schem- at these polnts ' ' '.' . ). t (,.., ., . to understand that the sm all Drem el atically in Figure 1 4 .4.. :, ,.. . ,p. . , . , uoto wheels cannot really be spun as First we will create a mounting for the

'.. . j/z zcjj rod ,.( , y., fast as they need to be for optim um cut- spindle and then add the motor and drive.

r . .: '/ :.iç.)i. f .:, ) . r tjng y'jjjs does nOt m ean that We Carlrlot Fi0 Llre 1 4 . 5 ShOWS the peri phery Of a 4

. USe them - we just have to be more cau- inch wheel mounted on the OD grinder..k Figure 14.3 Motor mountlhg arrangement as seen from above. The splhdle can tious about how we do it. The grinding wheel must extend past the

a/so be mounted yacing the other way The motor can be flipped end éor end. A high-speed grinding drive is best ac- mounting lo allow long shafts to be':

1 1 2 1 1 3 . . . .

.,.

:

.o,ve . ' . jarge motors and we want to avoid th at ,':''l2 ' ' .A. otor ,' on o ur Small I athes . )t,'vjae pjate that mounts to t he top of t l

leê

jy). ,.Tool post '

sf . compound slide has to be Iarge enough t tj 'ë''nelt : ajjow thesideplatestoclearthecom i'' '

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nelt : ajjow the side plates to clear the com-

i :j, .

' '

pound slide on your particular Iathe . Tlae $:....t )y '. '' . ' . . . :.'Plate does not have to be able to rotate orl .

'tt: '' t''''' 1athe Chuck tt '

.. J compound th e c o m p o u n d be c a s e th e enti re co m - . à)1.'. ' . . ' ' . ')' ,ound Car) be rotatcd OR lrhc CFOSS Slide. ilj' '' Hole to suit tool

(jj ,.pindle ) s inhe m otor for the t ool-post grinder ? ' Post stud Pigure 1 4.4. Tool-post grinder schematic arrangem ent has to be m ounted i n such a ' jt; ' 'elationshlàs. .aY as to meet th e following basic 5.

requirem ents: ''' k .' $ ,

yg rou n d . Th is re q u i rem e nt d OeS n Ot a p p Iy * M ove w ith th e s p i n Ie . s/4-28 COP Cto the quill mounted wheels on the ID * Not be i n the way of the w ork . l ,grinding spindle. Since w e know that a 4 . Not be i n the w ay of the operator

'.' '

.'

'

inch chuck will clear the top of the cross * Belt d rive m ust clear the w ork . . hSlide, we know that a 4 inch grinding . Allow f or easv belt adiustm ent .

. ' ' ' 'w heel m ounted at centre height w ill clear ' * Figure 14

. 6 Top view ofspindle m ountlhg. ? , ,.,the cross slide also . It also m eans that As w e did with the cross slide m

ounted ' ' ' :his is about the Iargest w he el that w e drive , w e can use a half inch rod that '2 Carriage centre distances between the two pul-can m ount on the OD grinder spindle un- passes through the plates for the com- ' ' '' ' l

eysess w e can fix it that the w heel is past pound m ounting to be the suppor't for the . I ' Th' e biggest advantage of a shafthe cross slide, then a Iarger wheel could m otor . A new belt of a suitable size w ill Spindle m ounted m otor is that it is easily m oved

e used. However, Iarge wheels m ean haveto be obt ained forthe new centre-to- .' 1/2 i nch rou back and forth and can be flipped overPerimeter of 4 inc: end for end in a few m inutes if it is in thegrinding wheel w ay of the w ork. The arrangem ent is also

. . aasy yo make and adjtlst. 1 3/4 by 4-1/4 by . . . Belt1/2 inch Plates s jndj e , , Motor . p . , caution

, , gase$. . . anye Safety is alw ays priority number one.t ..

, Motor : : 1/ inch clearance . W e have not given any considerationPivot ' : ' hOl for clamp bolt to safely as regards the exposed belt

j . . : :: : , . k . . drives in the above discussions. Depend-. u

' u . . , . .ing on how you intend to use your setup,

, . . 2 'I j ... ) . :....... ..-... . ...-.. ..., , . ,. -, --------- 'i---- -- . - ,-- -.- -,,,- ,--,.--, y-- -,--,d -I- -y- m -ke tl-e --------y

: :' fr top. mounted spindle. The motor can be offset to arrangements to ensure that you have a, ( , . : :. : eitjte, sjts ss can the spindle. saf e operation: ,:'

. j. This dimension varies . . . . . . . ' . . ..' ' ''' ' ' with you r lathe. Adjus . , .., . . . . .. . .. ,

. . . ., , , . . .

. ., . . ,. 2 inch by 2-1/4 ch by 1/2 to Flace spindle at c ter . . . . . , . . .., , , ,, , ) y ,.,y ,. .. , r . ., . x ,. inch plate on com nd helght of Iathe .' ' ' ' 7'' ,'' .' , . ' . ' ' . '

. ' '' slide . : , .' , ,. ' , . .... ? .. . ., . . , , p. . .

,

'.' ' ' . ' è '

. ;t ')$ .'. . ... : ' : . ' ' ', . .' . ,'., ':'. '

. '. . . .'

. , . i ..: ), .. .. . :. ' ' ' ' ' . '. 5 . .. ' ... . 1 . q ' .-. . .'. . . . . . ( '' .( . /' ): I ') .f ' J p , k r ''.,- .Figure 1 4 5 S indle clamping plates e/eva tion .k ? . r$,#y; ',t k .,., ..i? l' (. ,. ' . . . '' ' '. '

'. 1 4 $' r ' r 1 5

'.j

:.

C H A PTER 1 5 Number of teeth 2o ing as the spindle is mounted onto tlae. Material Brass vertical slide.

w idth of gear 0.250 in'- Hole through gear O.1 25 in Cutting the teeth

''. Module asneeded ltisbettertostartbym akingagearw ith

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. . Module as needed lt is better to start by m aking a gear w ith.

.) . . Type of t00th form as needed a few teeth (1 6 to 24) because you have

, ' to cut aII the teeth before you can reallyThe gear outline is first formed accu- see w hat you did, therefore few er teeth

a s .w. . : rately on a piece of 0.500 inch brass held make for a Iess painful experience. It isIe S O n U S I n I e S I n Ie S in a a-jaw chuck or, better yet, in a collet. also easier to cut teeth that are easier to

Form bolh sides of 1he gear 'to finished divide so lhat you do not have to w orry. . ': .

. dimensions - you cannot machine it after about getting the divisions right. Pick a' ' . the teeth are cut. The teeth will be too num ber that turns the dividing handle a

. . weak and will just bend over no matter full number of turns so you do not havehow sharp the tool. Do not drill and ream to m ess w ith the dividing head arms.

I imagine that the general feeling is that if directions. It makes nice 0.200 inch the inside hole just yet, we need the stiff- Twenty is a good choice but it will, ofyou can make a spindle, you know how square graph qaper. ness on the shaft at this time. lnstead course, depend on the actual gear thatto use it, however, this is not necessarily The followlng aspects of spindle use turn a true point on the end of the shaft you are cutting.true and certainly was not so in my case. are discussed: . . .. to indicate the exact centre of the gear. M ount the cutter in the arbor and theThere is a considerable Iearning curve ' Coat the gear blank completely with arbor in the spindle. Lower the cutter axisthat can be m inim ised w ith a Iittle guid- * Cutting gears for clock m aking . marking blue. This w ill m ake it m uch to the height of the Iathe spindle, nowance. @ M aking a dividing plate for a dividing easier for you to see w hat you are doing m ove the carriage tow ards the part that

The first tim e spindle user can use the head. as you cullhe gears. you had machined as 1he gear bîank andfollow ing notes as guidance for using the * Drilling cross holes. centre the gear cutter exactly on the cen-various spindles described herein. It took @ Cutting a keyway. M ounting the spindle tre of the point you 'form ed. Use a m agni-

m e a while to learn how to use spindles * Cutting a slot in a screw head. Rem ove the com pound from the cross fying glass to m ake sure that you are atwhen I first starting using them and * Drilling very small holes. slide and plug the hole it was in. the exact centre. Lock the cross slide bythese notes reflect the experience 1 have * OD grinding. , ,. , . W e are now ready to mount the spindle tighlening one of the screws that adjustsgained. * ID grinding. ' on the vertical slide. The spindle has to the gibs. The cross slide is not to be

The most important thing to keep in be exactly at right angles to the lathe axis moved ajain until we are done with them ind is that the sm aller the part that you Let us discuss these one at a tim e to end exactly parallel to the Iathe bed and gear cuttlng.are m aking, the m ore critical the setup is. clarify the needs and procedures: thus the cross slide bed. Understand in Next raise the spindle up w ith the verti-By critical l m ean that each and every Your m ind that m oving the spindle up and caI slide so that the cutter clears the out-aspect of the set up becom es very im por- Gear cutting down and in and out on the cross slide side diameter of the gear. Tighten the'tant. The system is now much less for- Read the entire section before proceed- Will no1 chanje any of these aspects of gibs on 1he verlical slide so tha't thegiving. ing. W e are not going to discuss how to its relationshlp to the gear teeth to be m ovem ent is a bit stiff . W e w ant to fix it

It helps to keep a shop Iog. Start a shop set up a dividing arrangement, just how Cut. such that the spindle will not drop dow nIog and use it - it is a very useful resource. to cut the teeth. W e are discussing tinY The spindle is m ade parallel to the turn-Never w rite anything dow n anyw here brass clock gears as com pared to Iarger ing face by bringing the vertical slide on , lexcepl in your shop Iog. Sketches, ideas, work. Which it is mounted up to a face plate and 1notes, dimensions, phone num bers, birth- Suppose that we are cutting a clock Securing it while it is up against the face - - - - - - - - - - - - - - - - ,

- - - - -

days, prom ises, lists of things to be done gear that has an outside diam eter of plate. Then m ount the spindle on the ver- Ih t ou did and how you did it 0 3O0 inches and 20 teeth. The specifi- tical slide. 'nd w a y . . .

Everything goes in the log. It takes m e cations for this gear m ight be as follow s: The spindle is m ade parallel to the Iatheabout a year to fill a Iog book and I use one shears by using a square betw een the Figure 16 . 1 Aligning the cutter with theruled at 5 divisions to the inch in two Outside diam eter 0.500 in Bhears and the face of the spindle hous- gearblank (top view).

x

, : s . . 1 1 7.'

. ' ,'

.

. . h;. ,. . .. .

' .. , ..- .by gravily as we lower it. Back 1he han- to each loolh (cul). The spindle has to be I/ ;(yt1.th ' . ' . i Making a dividing plale for a dividing ;.: . jj (jle up to tighten up against the nut. Turn low ered enough to rem ove half the m ate- i . eathe spindle ON and very slowly lower the rial at the Iand, the other half w ill be re- '' . There are tim es w hen we are called uponspindle and cross slide until the cutter m oved w hen w e cut the Iast t00th again . .y'. to m ake a special plate for a dividingjustgrazesthetopofthegearBackthe Loosenthegibanddonotallowthe ':) headorinordertodoaspecialjobThe

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just grazes the top of the gear. Back the Loosen the gib and do not allow the :) head or in order to do a special job. Thehandle up to take up the slack and make spindle to drop. If you want to Iower the $. holes can be drilled by the Iathe spindle ora note of the reading. spindle 0.005 inches, Iower it say 0.055 ;'$'' -; by the auxiliary splndle. It is usually

> -- easier to hold the part in the lathe spin-aking a cut across the gear, make a inches and then back it back up 0.050 yconservative estimate of how deep the inches. This is the only way to eliminate $g dle. This is so because it is easier to turnteeth have to be cut. This can be done backlash in an operation like this. W rite 7i up the form needed in the Iathe and then

. with a pair of calipers and a m agnifying down the dial reading - this is the reading :.. to m achine it in place, w ithout m oving it,

. Cv'.glass. Be conservative and w rile this we w ill w ork from the next tim e. . ls a x tyeoregcaf y

aptoos/l gear to w hen doing precision work. This m eans

. gtlre .alue dow n too . Low er the spindle by Retighten the gib and take a cut. i' yow soot/l tw m (exaggerated) . W e have to set up the dividing gear onslhis amount plus 0.050 inches and then M ove &he gear over to cut the next the back of the lathe head.back it up the 0.050 inches. This takes t00th and take another cut. lf the Iand .up the backlash. Tighten down the gib on now remaining on the outside is half of cutter does not have to cut any more ' o o ,. -the vertical slide and make a cut. Turn what it was at the Iast t00th, you are at than it has to on the gear itself . Cutting o o 1, o o-oklooo o

o ohe gear by one t00th position and m ake the right depth . Tighten all gibs down extra material wears aw ay your expen- oooo o o o o-o

-o o o o o o oO o <'O O k2 <# k2 O O O Oanother cut. You w ill rem em ber that w e and cut the rest of the teeth. The Iand sive gear cutter. How ever, there w ill be ' ' o o oo o O o o o o oo o O

o o oowere not going to discuss how this was should just barely disappear when the times when you will have to Ieave extra oooo OoO o o o O o o oo oo o oo o o o o

o o o oto be done (dividing head on spindle next t00th is cut. material to have a stiff setup. o oe ow Jooloooooo O O oo tt)o o O oetc.). Never go back to deepen a 100th. Keep What we are aiming for is a procedure j)f hoies o o o o o o o O o o O o One up O O O O, . moving forward and pick the last few that w e can foîlow that will yield a good o o o o o o o o o

oOo o o

o o.; à shallow teeth after aII the other teeth gear every time. Once we get that down O o

ooloooooo J oool o oo o O,.. save been cu.. pat, w e w il, w rite it dow n and follow i, --- - - -- --- ---- -

,...,

. chouc

okno

utnt

reij

ma

ojj

vteja

tehe

vegeetja

arjjba

l av

neku

fero

emn

tchu

et

rtejjlaigt

iwou

osrlkv

s'

wlthWyroitte nqudjopWmnenp lll edouor *110*/0* C 00 0* 11 1 0101012 o o C O o O o o o oo o O o j3 O O Oo o Oo O,:. and the hole has been drilled and reamed. skills is the target. o o o Jooooo o OM achine the front but do not touch the Gears m ade from plates have to be

, teeth. Then part the gear off a wee bit mounted to an accurately turned arbor sg ure 15.4 Dividing plate.' Ionger than the teeth to make sure that and nut and provided with adequatethe teeth are not touched . Rub the backing plates on both sides to allow

excess off on a piece of 40O grit emery them to be cut. The backing should com e If the opportunity arises and if you can. ' paper Iaid on a flat surface. as close to the bottom of the teeth as afford it, get yourself an extra chuck or

you may get a good gear if you follow possible. tw o, and get in the habit of Ieaving w ork

these instructions , but be w illing to do it lf you need lo cut a rack, it is bes't done in a chuck if Mou need to rem ove it fromFigure 15 . 2 Showing how cutter depth over if you have to. It is surprising how with the cutter in the Iathe spindle and the lathe . In this connection beginnersaffects çhe Iand. much you learn from cutling your first the rack mounted on an angle plate on are advised that a 4-jaw is more useful

gear. I made four before I was happy the vertical slide. The teeth have to be than a 3-jaw chuck by being more versa-Now with a magnifying glass take a with one. spaced very carefully and every precau- tile (a major benefit).ook at how m uch uncut m aterial is Ieft Drilling and ream ing the hole is the Iast tion has to be taken to avoid backlash If only one row of holes has to beon top of the t00th just formed. Consider thing that is done before parting off. errors. Large racks need to be cut on the drilled in the plate, it is not important tothis the land. W e want it so that the W hen you form the gear outline, Ieave as carriage with packing as needed because have the spindle at the sam e height asmarking blue just barely disappears when much m aterial as possible to make the a large cutter will not clear the vertical the Iathe nose. If more then one row has

de cut two, identical, adjacent teeth. So setup as stiff as possible. Cut away ma- slide properly. to be drilled, the rows have to be spacehalf the Iand w e are now seeing belongs terial from behind the gear so that the . ' , :. ' ;... . evenly and there will be a point where

. ,:.,. . ':1 1 8 '. 119

. . .

' '

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. ' .. ' ' .-. '. Use a sharp drill. ,, . ' . . ' re-oil every surface profusely w ith a thin ID grinding m ust be secure and well balanced at a1I. . use a high speed. . ., . oiI (sw or 1ow is oood) to wash awnw W hen considerin: an internal grinding high speeds.

. use a cutting fluid. every last oiece of Qrit. Heavv oils a-'l Operation, we are talking about taking The wheels and arbors used are. of. withdraw the drill frequently to ureases w Juld tend -o tran the'crit. -<' very small amounts of material off. Inter- necessity, small and must be used 'itclean and Iubricate the drill. - with small arindino s -lndle-. onlw = nal grinding often Ieaves the material care. Small wheels do not Iast Iong and it

.Itisveryhardtodrilideep-small,verysmalla-ountJfUaterial'can'b-' removedintheparthollowbeingground. maybenecessarytoreplaceawheela

7/23/2019 27 - Spindles


. It is very hard to drili deep small, very small a ount Jf Uaterial canb removed in the part hollow being ground. may be necessary to replace a wheel aholes. (This is best done by electrical taken off bv arindino. therefore aIl nar.. W e have to take the time to shut down to time or two before the job is done.discharge machining (EoM) by some- should be 'a-e as Jl 'se to size as '- os J-- remove this material every so often. Take extremely Iight cuts and workone else.) ble with only the slightest am ount of Small grinding wheels do not Iast very with great care to avoid bending the l/a

terial Ieft to be rem oved by grinding. long, just a few passes and they are inch arbors on which the wheels arem aDrilling-lholes under 0.020 inches in W e have one other problem that has to feadY to be replaced. m ounted.

diameter requires considerable skill if the be kept in mind - we have to keeo the lnternal grinding is a hijh-speed opera- It is usually not advisable to dress aw ork is to be done right. These holes threads on our grinding arbors in mi'nd as tion for 1he spindfe. Splndîe speeds of w hee used for internal grinding thoughshould be avoided by the beginner. If w e grind so that we do not loosen the betWeen 4,000 and 30,000 rpm are this can be done in the hom e shop w'ththey must be drilled in any number, the threads and have the wheel com e loose desirable. A certain am ount of care has mixed results. It is best to consider thesem aterial they are to be drilled into m ust as we grind. This means we have to grind to be exercised at these speeds. Things wheels to be throwaway item s.be selected carefully. in a such a direction that the Ioad tight- .

' ' the arbors onto the spindles and the ' ' ' '' ' ' :' ' '.' '' '' ' 't... ens . . . I . ' . . ' '

' ' ' w heels onto the arbors ,' ' ,. . , 'G i din ' . ' ' . ' . ' ' i ''' ' ' ) ' i . . ' '.'' ''', .'f'. ' ' n 9

' . . . Alm ost all grinding w ill be done with . ' ' .. ' '' '' ' ' 'the spindle at Iathe centre heicht. , '''i'. '' ' ' ' ' '

Setting up * 41:.'. . , '' ' .. . ' . ' .. .:b?.'.'''. .As a rule of thumb, it is best if no grinding OD grinding :: ' ' '.''' $is done on the Iathe. That said, those of Grinding on the outside diameter of the '' ' .. I . .us who do not have separate grinding part is the most com mon crindino onera- ..' ' ' '.'' '

facilities need to use the lathe for grind- 'Qlon undertaken with a too/-nost Wo Jnlna 1'' .i '' ' ' ' ' ' . ' ' . 'inq the occasionalpart, so we need a pro- grinder on a Iathe. '- ----- q? ' E ' ' ''' '.')à?.' ï. . . . .cedure to m inim ise the dam age to the w hen very Iight cuts are to be taken, ' f 'lathe feeding the w heelinto the w ork becomes ' '' '''' ' ' ' '

Before undertaking any grinding, m ake a problem . This can be alleviated by feed- ''ki. ' ' ' ' , ' ' ''sure that the Iathe is as protected as you ing in w ith the com pound set at 5.739 '

;i1'

can make it. strangely enough this degrees. At this angle, moving tbe com- ( ' ':have to clean the Iathe before pound along the lathe axis by 0.0010 Jl ' ' ' ' .6 '' ''' ' '' ' 'eans youtart. Doing so makes it easier to inches moves it across the axls o.oool 'fi ' ' ' '' .ou s

C'ean up afterw ards. inches. This is the easiest w ay to m ove 'l. t ' ' ' l ' C ' ' ' ' ' ' ' '''First set up your grinding operation but the wheel by 0.0001 inches. lèi: . ' '' ' ''' '' '' ''' .''

do not grind anythinj yet. Movements at other angles can be ) ' '' '' ' i ' .5 ' '' ' '' ' . .'

Before you start qrsnding, get some oId achieved by mountinu the comoound at f ' . ' 6 ' . ' ''newspapers and some scotch tape and 5.739 degrees to the 'nale bein nround. ,1' : ' ' ' ' ' '''''

i he Iathe and around This means that the axi Wl positiW Wing has :'F' ' ' ' ' '

''' '

r ' ''7cover everyth ng on tthe setup w ith the paper. to be done w ith the thread cuttinn screw î' ' ' ' è' : '

After you get done, do a thorough and its handle. Grinding at an angWe to the 'b6'' ' ' :' . ' ''r''' ' ' '' 'cleaning up job on the lathe with particu- lathe axis is a difficult orooosition if acctp ?' ' ' ' 2 ' ' ' 'J7' '' ' 'Iar attention to the w ays. W ipe every racy is param ount ( 'hi-h it is or w e '' ' ' ' ' ' ' ' ' .

' ' ' ' ' ' .

'kLp; .. ... .ï .. .. .- '. ', .. ' .. . . '

smidgen of dust off every surface and would not be grinding). ,( , ' , . .ï: s..q...- .:)t '.;) . ' .'4... J ,.;..' .. . . .''$ y- . .. '.'. ...-J ...- tl. '' $..ï I .' ''. . -? . '. ..I ,$:.., .. .- -.s'. ., 't: ' '. I . . . . . . . .. : . ...; .. . , . t . ., .:. . . . . , : .. .

. . $. t .. ' '

. . ;(. . '.

. . ,.. , ,y .,.j .,(

,z . , ym.u1 22 g,

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' ,.ï . ' .--..,. ' .The purpose of these notes is to support either 0.400 inches or 0.500 inches are l . ' ' ' :' 2 - ' ,'

' '' '---- .the spindles that are to be built. the diameters of choice. W e w ill m ake i'' ' . t' '' ''' Z'EP

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As usual tlnese notes are intended for them with a diameter for o.soo inches '.. .. ' '. - 'beginners .

because we probably do not have a o.4oo ,F' . : .. ) Figure 16.1 Machlwst s button., .The follow ing item s are covered: inch collet for the Iathe. M aking them i

' ' ' '

.ythus allow s you to subtract either 0.400

. M aking a set of centring buttons. or 0.500 from the measured dim ension to àxactly 0.500 inches in diameter for a Thicker washers may be m ade if you pre-2 Aligning a la&he headstock and get 1he centre-lo-centre dim ension of the ,1length of 0.500 inches. Just barely bore fer. These are best m ade of scraps. Drill

tailstock. two Iocations that the buttons occupy. r the hole to clean it up. Very Iightly cham- 6-32 clearance holes (No 28) in 5 pieces3 Cutting Iarge threads in two passes. The buttons do not have to be hard- fer the face edge. Polish alI finished sur- of /le thick brass (or steel if you Iike) and

4. centring a part in a 4-jaw chuck. ened, but hardenino them will make a faces with emery paper (200, then 400, clean them up with a file. Screw them5. A mandrelfor Iocking the spindle and better, more Ionaer-lastino tool for vour then 600 grit with a drop of oil). Leave a down on to a 0.375 inch mandrel with al te for simple divisions . collection. - - ' ' 0 .070 inch base flange and part off the 6-32 tapped hole in it, held in a 0.375 p a

6 . Dremel Moto spindle nose dimen- Iam going to describe buttons that are (;piece. Make three more pieces at this inch collet. Turn the outside diametersions. .. slightly larger than those usuallv seen as , size and one more that is y' inch Ionger down to 0.450 inches. Lightly chamfer

. hese wijl be easier for a be 'inner to on lhe 0.500 inch uiameter part. à1I edges.make. set up your collet for yz inch work.

Making a set of centring buttons* start out with some va inch diameter Place one of the buttons in the collet with Screws stock. I picked this because it is the size .:the base end out and face the base to Purchase these as socket head capIt is essential to have at Ieast one cen- of the base on the buttons. Use either sil- . jive a finished dimension of 0.063 screws if you can. They look so nice. Iftrinj button in your tool collection. It is ver steel (if you are going to harden EInches. With a boring tool open the W not, five 6-32 (approximately 4BA)deslrable to have a set of one Ionger one them ) or m ild steel. ,inch hole out to 0.375 inches in diameter screws w ould be ideal (sm aller sizes areand four shorter ones. If w e are about to Take a close Iook at the draw ings . . and 0.437 inches deep. Very lightly harder to work with) so we will make ourmake one, we might as well go ahead . chamfef all edges. Do this to al1 five hold down screws 6-32 (approximatelyand make a set of ' pieces and kepp in mind that one unit is 4BA). We need 4 screws % inch long andith them . M ake tlae four short buttons first, one at . Ionger. one screw x inch Iong. w e need Ys inch

It is qreferable thatthe buttons be of an a time. Make them with the base to the ' of threads on each screw. Make themd meter dimension. AIl the buttons lathe chuck. place tlne w inch bar in the 5washers out of x inch mild steel stock. Cut thevOnuld'lave exactly the same diameter

l-jaw and centre. Face tue uar and cen- '.we need five washers for the top of the threads with a die held in the tailstock tore drill it. orill a x inch laole 1 w inch .'buttons. Eacla has to be o.4so inches in get tlae threads straight. part off the

*Known as toolmakers' buttons in the UK. deep into the bar. Turn the bar dow n to diameter and 0.063 (716) inches thick. heads slightly over Y1s inch thick. Turn.

j 2 5 24' ) .,.(.'. .

.'

.,'' .

kround in the chuck and carefully face on a Ievel surface (or a surface that has j s tudv the follow ing diagram s. These Under no circum stances do you wantevelled). It should indicate a Ievel .'' ' lathe m ight cut

.your lathe lo cut a taper like &he onehe screw heads to :)$s inch high. Cham - been h ow three ways that a

er edges. Cu1 1he screw head slots by condilion in all directions. jj ere w e are talking about taking a cut show n in Figure 1 6.2c - you will haveolding the screws in your tool holder set Next we need to m ake sure that the ith the Iongitudinal automatic feed and trouble getting 1he bearing and otherp at the Iathe centre height and use a head of the Iathe is exactly parallel with t with 'the manual compound feed. parts on to the part being turned and theno oa2 i

nchw idesaw tocuttheslot theIathebedThism eansthatastraight

7/23/2019 27 - Spindles


nch w ide saw to cut the slot. the Iathe bed. This m eans that a straight , w jjen m aking these cuts: try to position they will ge1 Ioose right aw ay. This iscrew slots are to be ?Za2 inches deep. preferably ground rod held in the chuck tjne tool close to centre height. lt is not totally unacceptable.1 b urrs. Carefully cham fer alI w ill be com pletely parallel to the lathe jti cal but the closer lo centre height ''' ,emove a credges. . bed at aII points on its surface. This can vou get the better. If you m iss centre... , . '

dial indicaAor ' jae hyperbolic cut you would get 3 . Cutting large threads in tw o orbe checked by traversing a jjeight, tase m ounted on the lathe carriage back and is very slight and m ost amateurs w ill not m ore passes

A base is not essential but is a great de- forth from one end of the bar to thebe able to m easure it.ven

vice for keeping your buttons, washers other. W e are assum ing that the chuck or yf y ou can get the Iathe to cut perfectly If you are cutting few er than 1 6 threads,and screw s together. M ake the base collets used hold true. arallel as show n in Figure 1 6.2a, you you m ay w ant to consider cutting the) is is done torom W inch brass (or m ild steel). Brass The same should be true of the ya ve the perf ec1 condilion. This is w hat threads in two passes. Thw ill make the thread cutting easier. The tailstock - its barrel should travel exactly w e are striving for, but if you are unable redute the cutting forces on the tool by

ase is going to be W inch thick by % parallel to the lathe bed. t o attain this condition perfectly do not reducing the length of the flank that thench w ide by 2 % inches long. The five 6- The Ialhe spindle and 1he lathe worry unduly. Cutting tool has to cut.2 th readed holes are 3/0 inch from cenlre lailstock quill should be at the same jf you m ust be Ieft w ith a taper, then a Let us assum e that w e are going to cuto centre and 0.438 inches from each height above the bed. This m ay not actu- tt lat gets fatter as you go tow ards 8 threads per inch for a Iarge screw . Foraperend. Make sure the threads are exactly at ally be the case but is often assumed to the headslock is 1he pref erred condilion ease of discussion Iet us assume that

right angles to the base. File to slze. be because there is no easy way to fix yk gure 1 6.2b) . This means that the bear- these threads have a 60 degree form .ham fer aII top edges w ith a sm ooth file this problem . It is a matter of scraping j ngs w ill get tighter as you push them The pitch of these threads is 0.1 25and polish w ith em ery paper. Lightly oil. the bottom of the headstock or the t o the shaft that has been turned. This inches which m eans 'that the thread flanknount the buttons on the base and they tailstock and as this often does m ore i s tolerable. is 0.1 25 inches wide. On the Iast pass,

are ready for your first project. harm than good it is left alone. (The fac-, the thread and tool m eet along a fulltory usually provides m atched units but o

. 1 25 inches. This is hard to cut and aan old latbe m ight have the headstock (a) very sharp tool taking very sm all cuts

2. A ligning a Iathe headstock and from one Iathe and the tailstock from would have to be used.ailstock another and this can cause a misalign- l A better method is to divide the workment). up between two or

, better yet, threeligning the headstock of the Iathe to tbe The only adjustment we normally have ' . , ,

, . passes. The first pass cuts only a third ofb) 'ailstock is m ore com plicated than it availabte to us is the ability to m ove the th e full depth of the tbread, then the :ooseems at first sight. I will describe the tailstock at right angles to the Iongitudi- i s moved over one third of a 'hread anddeal setup and you can decide w hat you na1 axis of the îathe. For this reason , the next third of the threads is cut. This

want to do on your m achine. m ost am ateurs concentrate on this c u't ends two thirds of the way into thes a rule it is considered desirable to adjustment. However, it is worth your ( o) , , , thread w hen the flank starts 'to m eet theave the bed of the Iathe absolutely Ievel. w hile to know exactly how your lathe is fi rst third of 1he w ork.his is done to take the twist out of the set up. , Move the tool over again and make the

d On a sm all Iathe this is not very The cross slide should m ove at right thi rd set of passes. These w ill end al 1heathe be . I to the Iathe bed and exactly so . If . full depth of the thread and will againm portant because a short bed is not ang esIikely to twist very far, bu1 on a 40 foot there is to be a deviation, it should cu1 . . . . meet the flank cut previously. lt is nowig ure 1 6.2 (a) Thls FS the Ideal condltlon -ed this might be a big problem . A bed is the part being faced slightly concave. /f. you mgst have a usually necessary to take a finishing cuterfect/y para//e/ cuns; (b)sually levelled w i'th an accufate spirit This will allow parts to sit one on another

js tvpe s/.taper; (c) to finish the threads. 'aper thls Jà the acceptabIevel, often referred to as machinist's lev- without w obbling and m achined shoul-do you w ant a taper ,Llnder no circumstancesls. A level can be calibr4ted by placing it ders to seat tight . . ,, gke rs:s - t.t a totaqv unacceptable. ê ''

j . . j 2 7 2 6 . t . jtL

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..

. r . once you get within about 0.002 dIe rotation. It w ill be accurate enoughv . inches of centre, you can start tightening for m ost applications though not, of

,, , . , , . ., down on the jaws selectively to bring the course, as accurate as a proper dividing. part to the exact centre. lf the part is head.

..

, ësticking out of the jaws Iess than an inch If you are going to do work on a part. or tw o, the part is centred and you can held in the Iathe spindle, it will be neces-

7/23/2019 27 - Spindles


. . ,p y p ,. proceed w ith the turning. sary to hold the spindle very firm ly w hile

'j

nrstpass seconupass .. . ' n irdeass . . .you do the w ork. It would also be an ad-

. .. . N ote . . , vantage if the spindle could be indexed,

'

no not strike the part w hen the dial indi- through 60 divisions. This is a useful ' Figure 16. 3 Taking the three sets of passes to cut coarse threads.

cator is in contact w ith the part or you num ber and allows you to divide a circle- are likely dam age the indicator.M ove the into 2, 3, 4, 5, 6, 1 0, 1 2, 1 5, 20, 30 andt

4. Centring a part in a 4-jaw chuck Approach the work slowly. Do not Sindicator back off the part with the cross 60 divisions. The most obvious omissiontighten anything dow n too tight too qslide and then make the adjustment. is 8 divisions. Sixty holes can be accom-The 4-jaw chuck is probably the most early. Rough centre the part in the chuck .

m odated quite com fortably on a plate 6versatile part holding in the arsenal of by eye. You shogld be able to get w ithin lf the part is s'ticking out m ore than a cou- inches in diam eter. This is by far them ost amateur engineers.As such, the about /1e of an inch of being on centre P1e Of inches, the outer end of the paft m ost flexible and useful dividing plate form astering of its proper use is a Iong-term w ith a Iittle practice. should be centred also. This is done by you to have in your shop.undertaking. This m os't basic skill to be M ount a dial indicator at lathe centre m oving back and for'th betw een 1he tw o Note 'the follow ing:

ja cj making adjustmentsastered is the centring of a jart in the height and make it approach the work ends of t e part an4-jaw chuck so that the part Is centred from the side you are standing on. Find 'tO the outside end with a Iight mallet. The 1 There is a Iarge gearbox cover thatalong its entire Iength. the highest poin't on the shaft and loosen idea is not so much to centre the outside extends past the back of the spindle

It is often important that the part being the jaw on the side opposite it and 'Of the part as it is to keep it parallel to the on most Iathes to accom modate themade be centred in the chuck as accu- tighten the jaw at the dial indicator - but Fart near the jaws. In that way, as the change gears. The indexing assem-

d the outsides will move bly has to extend past this so thatately as possible. Older 3-jaw chucks are not too tijht just yet. Work between 'IaWS are centre ,

'otoriously inaccurate holders so the 4- these two Iaws untll the oart is centred with them and the part will become cen- the cover will not interfere with thejaw chuck is used when parts must be between t-em , then shif- to the other 'tred as a w hole . By the tim e you get hold down arm . You w ill need toheld accurately . H o wever, just centri ng two jaws and centre the pa rt between

,djlo

ow

unj:

tojx tjohmtepnje ntgejythpea/aajwjssj ., y'tjjs j pjoaartj cjhceucjakr tjahtl sdiamsednasj jun; ftojjrs yjsosujtjjaor;he part at the chuck is often not enough tlaem At tlae end of this exercise, the s

to get the job done right. w e have to part will be within about 0.010 inches of .tightening will centre everything. the expanding shaft that extendske sure that it is centred along its being centred . There is a certain amount of experi- into the Iathe mandrel accordingly.aentire length. On a small Iathe like the Now rotate the part slowly by hand ence and getting to know your chuck in 2 The length of the hold down arm has

Myford s7 the small opening througla tlae and stop at each jaw. Make a note of the these centring procedures. once you get to be adjusted to suit the Iathe.

ia Iauck responds to mounting and table in your shop. Itcl' nwdl;umeeoaun,sstkumeubuocfn.tOurrldeinluoofueWruYroy should be designed to go down at 45centres. This makes centring the outside point on the dial indicator is halfway f degrees as shown to minimise theend of the work even more important so between the high point and the Iow effects of up and down and side-that an accurate centre can be drilled in it. point. Now the zero poin: gives you a : 5. A mandrel for lockinj the spindle ways movement between the Iathe

The first thing we do is go over the part rough indication of where you are trying and a plate for sim ple dlvisions and the table. The best compromisew ith a Iarge sm 00th file to take out alI the to move the part to as you m anipulate is 45 degrees unless you know thatbumps and scratches that are proud of the jaws. ln this discussion we will discount the your lathe moves in some otherthe surface. This will make the part lf the part is high, tighten thejaw at the Fossibility that you already own a divid- direction with more ease, then theeasier to centre by eliminating alI the dial indicator a Iittle more snug. If the part lng head and have a way of attaching it arm should be positioned such thatbum ps on the surface of the part that is loose , just barely Ioosen the jaw. As tto the Iathe spindle for division purposes. the movement of the Iathe does nottend to make the dial indicator needle you go around the part the part will start This is for beginners and is a sim ple w ay m ove the relative position of thejump. to get closer and closer to centre. . tO provide 60 divisions on the lathe spin- plate to the Iathe.

1 28 ' 129

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. o g 'k... . . .. .. ... . , .. ' Arm Nut ' kathe mandrel stops p'it . ' .' )''' '' ' i. . . . . . . . against this shoulder ' '. . '.. .', ' Lengt: of arm to suit

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, ., ojy jts yench or jable .

' ' This dimension for your ?) ' '' ' ' '''''' '' ' 1 the must clear the cover ''' t ''' ' ''' . '' . a ) ,

, . . at the back of the lathe. .. ; . ' . . :. . , . .. , , . y . , Auachment arrangement. .ïF r .t

,1 , k ,,, , ( , , , .. ,: yj. , , , . y ,, ,, to sujt what is on your' .' a(.'., . ,. , o

(b) . . . ' . t ' ' ? . Iathe table11 . ',, . . ,.( ; , , L '.' .

' ' ' Figure 1 6.4 (a) Section across the simple indexlhg assemblv; (b) Indexlhg plate with 60. I ' ' '1'', . '' . . . . .,, 1 ' ' dlvislons - onlv 12 dlvislons would stlllbe verv useful; (c) Back elevatlon of lbdexlhg assemblv.

. 11 . .; ' .l ('' ' ., .:: .I ,

, 'The spindle of the attachm ent expands The plate is made from 0.1 25 inch' .. . .' . . , in the Iathe spindle and becom es a part of sheet steel to give it the stiffness and

.i y To suityourlame j,it. The division plate is a close fit on the body that you will need to attach the' / . ' . spindle but is free to turn on the spindle holding arm . On the face plate, bore a 1. . . , . . . .(. .:

, '' - - - - - - - - - - - - - I- - - - - - - - - - - - - . . . .,'.è :body. The division plate is attached to inch hole at the centre. Use the plate ar-

l . .., the Iathe base (or mounting table) by a bor to spot the three holes that hold the

I , stiff bar - this bar keeps the plate from plate to the arbor. Attach the arbor and' . tating , i.e. once installed the plate does m achine the outside of the plate in the 4-. roI R=3.000 in1 ,,not rotate. The spindle rotates in the jaw chuck after accurately cen&ring 1hej .

plate and the indexing arm is attached to arbor. The 60 holes in the plate have to1 . : ; the spindle. A pin on the arm can be be drilled w ith the aid of a dividing headI '.. ' dropped into any of the 60 holes in tbe of some sort. l suggest that this be done: ' ,'dividing plate to perform the division by spotting the holes with the dividingl . 'needed. All parts should be made to fit head and then drillin: them in a drill.. j ,, ,, jj 4, ,, ., ,, j j

. .l . ,.t ' . closely SO tnat tnere IS mlnlmal play In press.'' , , ' ,j,.j,,j

' l :' . .'. ''t2 . . , , . ., . , .1 30 1 a :fi:' . '

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. Dremel M oto spindle nose taken from an actual closer and its col- (c) ,dimensions Iets . vou should check your specific tool- :, 0.711 in overall '

: ..ng to m ake sure that it is identical to the. . 0.345 in 0.266 in

The Drem el M oto Tool collels and colle't inform ation given here. It is unlikely that ,'');.loser are used on a num ber of the spin- metric tooling will be to these dimen-

dles. The m easurem ents oiven here are sions. '

7/23/2019 27 - Spindles


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. ' . . ' J.' . I , . . ' ' ' . . . ? j

. I .' , h . .$ 1 , , j tr jtja.. . t . ' ' '

,: Ue S j.. ' . , . . , . . '( . .. .) ,,q , $ ,'.. . ,... . . ,. ,. . ,,. : 2 x 1 0 m m j

' ' ' '

7/23/2019 27 - Spindles


. ï., . . : j. . . , . j.

' : , . Recess is 3.0/ . .J . . ,, ji j mm deep, . ; , jj , à ' 1; . . . , .. . . .. , , j . 1' ' . f ; . ' ;.. j ' ' . 1

. ' , . ) . 4 , . . . . , z m m sjot 3 m m, .I h . . . . ' . , .. . 1. ' 1 '.

' . . . . . . ' '. 1 . . J L , : $ ' :

Please note that only dimensioned drawings are reproduced here - non-dimensioned l''i) . ... , ,; ' ' 12.7 mm lk . .t . 180.0 mm overell 12.7 mmraw ings appear in the relevant chapter . ' k. ti . ' . . . ,,

' F.. . . . . ? , , r ''I .

- . ..

. j . .. .. à, bearings' . ' y ,

'' ' 50 mm CaheGk 12.0 8.0 mm,. rJ 24 x 1 .0

S 4 3 2 1 6 .' I ?. ... .$ . I Key. . ï(. .110.00 mm ' '. '

.)' ' ' .ï . . - - - - 1 0.0 mm thru hole - - - - - - - - -#2 Mors taper- - - -.$ $4 .tj5(,:, 20x 1 .5 2s o() mm dia

. 2. ' , ,, x .o mm dia 23.: mm dia$.:. 38 .00 mm dia

.j' g , . - t- . . ' '. . #2 Morse Taper (j 2 ' Standard Myford

- ..- .. . .- . .- . .... .. . ..- ..- . . - - . ..- .- . .. . .. ..- - . . .. .- . . . ... . .y; :t. Regjster and threads.

l.'Fl' ' ' . ' ''l' , yjgure a .7 secyon s/opg the sp/yà/e.' .' :. , .

$ï ' . .. . '. . . ..

' LL ;' .. . 1, .. T'.' ' '

. I. . .q , . . . , . F,.., . . .. .

. ' '' '' 1 '. : ' '

. . ; , . l . . . . 55.00 mm ' ( . .: , B r Br . ''. . i ' ' '

J. ' r'

j'. . . , uut recessigure 3 . 1 Cross section of a cartridge splhdle. Note. besides the beanhgs there are only 7 t; '. ) '.(. Bearing recess 45 .0 mm hole8rts CO be m ade. .. . , . '

,, ,.: see text. Bearings (2).

' . ' '. :'

. .. . t, - - - - - - - - - .- - - ..- - - - reGess

. , , s . . . . ,. . , / j ..,. j mm threads . . ' ' ( .. , . , . . . , :$ mm dee . . , . . ) p

. , . $7 . . .' I ; ' '. ' . ,. . . , , .

. ' 1 ; ' '

' )' , Fjgure 3. 1 1 Spindle housing.

J. ' ' 1 a 5 34 . :

;

1 .so mm 42.25 mm55.0 mm dIa ) gg mm Ojefajll .'.

o 75 mm 's0 mm .I 38.0 mm dia

:;.8 0 mm 25 mmo suit belt E' '

2c c mm 7 mmReam 20.00 mm 1 .- - - - - - - - - -. .- - - - . z. .- - - - ..- . Figure 4. 5 Studs for mountlhg splhdle.j )

,ztltomm

7/23/2019 27 - Spindles


ztl to mm ,

(j1 ') - Drill 7.5 mm - - - ., 'Q.t 24.% mm As needed through

'' 1 j20.0 mm .. chamfer

- ,. rs tbr m ounting swww/e. Figure 4.6 r nu

Figure a.2o section across the pullev/puqev dimensions. ' edges '

Figure 4.4 Optional spacers for plates.cut recess in theads '.

j . 3 () mm deep ,, . k k . , . . )' . . . ..

' .. J . ) '. . ..- ' - y .. 7:.35 mm on centers ..* . .zo () mm ' . '' - .4 - - - p - - - .- .. .. .. . :. j

. j .. 20 X 1.5 .. j j ( .. ) .. , J . .. ,. . * ; ''. ''.'k ' $'.'T 7 3I Turn down to .

'

l lo 0 mm thick ?'

Figure 3.21 M odification of a comm erclàl 20 x 1. 5 nut.3

10.33 mm 50.0 mm 15 mm )

E0.0 mm 5c mm square . EI l I j I j -I- 1 - - (Bj I sj j Q I I I 1 1 Figure 5.1 A smaller Morse No 2 splhdle housed /W a 5Omm square bar houslhg. roI j 1 1 I I ,1 () .() I I I 1 1 I '' .1 1 I l 1 I I I ) .mm 1 1 a.27 ss mm l I 1 j l1 . I J j j j j , q ryj ryj- - - - - - - - - -

I so mm , ,.

- - -

. , , , . 26 c mm dia I I j 1 I 1( . . z'- ..0 mm I I l j j j Il 1 . -

22.0 mm dia -. -. x l I l j I I k I . ''' '-' xx. z.

I I 1 1 I I t 21 ,0 mm dia ; 1 &l 1 9 1 I 7 .5 mm 1 I I .

l l I Ul () I l I jjojes l 1 I ( 32.0 mm di2 . - y - V - / t.'1 '.'. 1 I I l x 1 .. .. 1 I typicaj -I- l -j- lt/mm w ze ''-

I I I -a mm by a mm Ig

100.0 mm ; Spanner slotl

' ..Figure 4.1 Clamp plate dlknensions. q Figure 5.3 Front beanhg, lnner race clamplhg nut.;

36 , 1 37t

E E $g E E : .

E . .? ï trlo CR z q 110 . co mm a) to ,38 mm

, . I .,<. J,

?- - - - - - - -10 0 mm hole through spindle - - - - - - - - - - - i' t

.' , . '

2000mmdia

7/23/2019 27 - Spindles


,, . 20.00 mm dia. ,' I . ' .. / . ' ' h ' ' '' '' f

16 00 dia ' 20.0 mm dia 1.125 in '': ' . . .., ,.. '

$ ,'

, . ,j . . .; Figure 6.1 Section across the zn/cro splhdle. ' ''.r'' , . . . ' . . ., . . , I by 12 tpi j' . .. .,'' . . '. ; ; .. 35 , 00 mm é . .. . .. .. . . . ) kI 1I 1.... . .. . .. , b ) A. , . .. .. ... ' .Figure s.s smhdle okpenwons. . , , , . ' . , . . , ,. ' ..., . 1c.00 m m or to

:j . . , . .?y , .I,. , ; ig gg mm 8 gc mm 2.50 mm = ' .

; r j . ;, r jy y r- 'I . .. , (19.65 mm :. . . . .,

'; . ,,26.0 mm .,... . . :. ,., ,,, $. 0.270125 mm Overall ' ' ' '' j.

, x 40tpi; ,; 7 nj

' j.j 3c mm dia.--.:-- , - - - - - .ream 3.00 mm - - - -7 mm dia shaft - - -

E3trwllnH . or to suitBack bearing recess Nut dearance é : bejt) 7 -hj .' , 28.0 mm hole in housing 1 t/mm '' jz cc mm dia

. ., . ' .

) ' .I,. . , .' . ' <'

; Y ; ê ?. . r. . . . Figure 6 . 2 Splhdle nose de tails. (. mm wide SIOtS r, 1 ' . ''.. . . .. . .' ) . . . .

'.'' Fi. ''':1i.i , . r ; , . . ' k .

l R is housing is to be made of 50 mm by 50 mm bar stock. , ') : gj. '. . . ' '. ' J ' . .

.p.? h . . ' . ' , ( ' ' Fjgure 5.8 Details Of housing. . ' ' ' : ' - '- -' - '-' - '-' - ''- - - - '-' '- - ''- '- - ''- - , , ,l i, ' . . ' . . ' I

, ' . g: ' . , ( . . , E E 6 E ':' E E E h .

' ' . . - - . . . q y Figure 6.3 Spacer dlm enslons. ' t . lq m q : . (E . v' v- D . . J

. . ' l 50.0 nlnl dia ' ' .. , . . . , . ,. '

., j , ,' . : J ' .' .

' .. 25.0 mm dia 2 '''' 1 10 0 mm housing' '. 1 IJ '. . . f

, 2c,0 mm dia. . . . ., . Ream 16.00 ' ' . . .

, 'r j .' . . :.

' ' ) . . 1 ' ji ' OSe. eO . ' . j ' . .16.0 mm . . Bearing are to be glued into the housing (Loc-mte)

. Figure 6.9 Drivlhg pullev. ' '';; ' ' Flgure 7 . 1 25mm diameter spindle w#/? Motor Drem el Tool nose.

' y8 t 139

.' . ' .L

A , 1 10.00 mm housing ,. ', t' ;

. . . ,'. , . Length=gs mm totalto stad with' ' ' '' ' ,

' Figure 7.B Spacer dimenslons (see dlscussion J'// Chapter 6).:

22.00 mm dia - - - - - - - - - - - - - - - - - - - - - t , ,75 d 1 7 i 1200 di

7/23/2019 27 - Spindles


, ,7 5 mm deep 1. 7 mm incues 12.00 mm dia

,. j; x 1 .25. nut

. I ' . 20 mm ID 25.00 mm dia ) :

Recess same depth Recess 1.00 mm . -- -- -- - - - - - -- - - - -- -- - - - - -- -as bearing deeper than bearing 1 - '

...' . '. Threads andFigure 7.2 Splhdle housing dlknenslons. . ( register to puljey to matchi.

, j. , ,. ,, , majcjjcjjtjck gg t;tl mm dia 17 5 mm hole the belt to be' ' ,. . . .r (jsed oo mm . . . .

2o.co mm o.so mm j2o c mm ' 13.00 mm Figure 8 . 1 a2 m m diameterspindle with Jacobs /s chuck threads (it can also be made with E 'E ' the Moto Dremel Tool nose on it). . . ' : ''.' ' . c ' '% .

10 00 mm dia CD ' ' ) . q 110 . 00 mm ' . .

j '10 X 1 25 17.50 mm dia thru hole.0 . 00 mm dia . . - - - - - - - - - -- - - - - - - - - - - - - 32.00 mm dia. . . . . 7, ; , .î .> .; .

M oto Dremel Tool ' '.

Nose. See Ch 10. ' '' . . . .

lr Figure 7.3 Splhdle dlp ensions. .. .

. . . j. Recess to match deeper than the .. Ci ,.. ..... . . . .. ( . bearing beafirlg Used ' ' '

, , y7 . :.; . Figure 8 .2 Splbdle housl'hg dimensions.

. .k :.. h.... $: f a, .. .. .: ..f.? .. . ç.:, . $ I s 68 f . :.. .: ,' ' .

. . . . . . . .

20 0 mm . ' ' ' . .. 0 m m ? '

32 0 mm dia 1 0 mm inches 1so () mmj '. 0 mm l2 .0 mm dia .

., . h t 16 0 mm10.0 mm dia ream 6 ' ' .: . ' 12.00 mm dia push fitI . ' l J 7.00 mm

. ,.. ' for bearingst t

'

hole thru pulley - - - - - - .Pulley width .'l '' ' and belt groove 12 X 1.25 threads for 15.0 mml Tbreads and registerto suit your belt à .'.' ' . ?;.. ô. , ' to match the chuck

.20 degrees ; to be used

> . Figure 7.4 Pullev dimensions. , $ : ' Figure 8.3 Splhdle dlknensions.:

0 141'

) '

. . . . . ' g . . . '. . . . ..1.. .. ' '

. 32.0 mm dia ... . . . t ' t* ,'p I . ... I rc ç. .2.5 mm 12.0 mm . t lt/mm

'E ' 16.00 mm dia . ''- 38 (ào mm. .. .l . ... j. , .'. h. , , ., q l .. To suit

I .'. ' ' ', L, . bearing12.0 mm ream I . ;' / ' j

' 4 jj

7/23/2019 27 - Spindles


. .. 4. .. . . . . . . . . , ., jj,. , ,t I . 3 mm 20 (m mm dia clearance

. . gr j 5: mm. . . . . , , , , . t' $

. ' l 80tll sides of ' '.. ''.,? I . ...S ...h.. .. .. ; . . .. l ' '.1 ' 2 . ' 'rex onl. ' the hotlsing are ' .

. ,l ' .''$ ' ' Pujjey groove to Suit ' '' ' ' ' ' %* Wh*ê* t ' ? . ... r . ..a .. .. . . j yjj tj j

J' ,.. . .. . Figure 8.4 Pulley dimenstkms. ''' .' ' Figure 92 Outer houslhg ëipenqwbr).s - the ends are ldenticah

. . ' . . . ' . '. ; ..h ' . . .: , à j ' : I ., ; .. . , , t . ' j . ' . 7 . ' 38 0 mm dia. I ' ' J) 'k'.. t tj . . 1. '

) #-+' 50 mm x 2 ' ' ''

.z' lt/l'nm to match I lvmm

.. , , y j ,'

, , jjousjrjg tjjreads. l. ' . . .

'. . '. v '

t.. 's ' '' :?'' . i '.I

' . . ' ( t . . '12 o

-r.nm hfltreanl?d ' L , ' ' l- - - - - - - - - - - - - - - - ls.co-- oo .. . ..,. . c.o, ,-,,-

,' '''''''' - - - - ' .' . ' :.

. . . . ,; j ' . : ' I than spindle. .

' ':' S .. .. .y '' . . . . . . . . ' ' .

1 .' I

. . ,.. : ' ' '. . 1

I , . . j ;., yj g g g y. . , .,s , . , ,, ,,. ... .( ;tICP . NGCW /fN&flWO/1& ' 'j I '' ' . . .' . j . . :... . .. , . . . . I'.. k ).J ' . . . ' . ' f 9 '

S . . . ' , ' i ;. ' ' I ' ' 5 ' '' ' I ' ' ' ', . 1 . . I

' ; . .. . . .k . . , ( '. '' . . . ' . '. . . I . . t ' ' . .

C n ' ' ': , l .' ' ) . . . I .t .. 5ë

I '-;- 100 mm wheel outline ' . ' ' ' ' . . I 1). . 1.' '. l I . .. . .' ,. . .

. . j. ' l .. ,I I $. .. jv . . . . ', ? , , ., . . . a.0 rnm by z.0 mm. , , , .? cc mm. . l . I 100 mm housing ' .. ' . ' spanner slot. . I ' , j j . ,. aa mm : . . . . .. l ' Figure 9.4 Beanhg cap dim enslons - two are needed.

. I ' . 'IL 11 .1 '

l '' ' '' ' '. . I . h ' ., . ;j , j. , 135.0 mm (not overalll)

t . . h 9.00 mm 0.50 mm 12.0 mm. . ' ' ' . '

l : . ' ' F . ' .I 1 .'' ''. ' n' '. l '... I . ) ''' - - -. . l I .

j j Make wheel plates to sklit 'i l your Wheels . Match the ''' ' ' $2

. ' I I . ' Details of arbor '' 1 '. . blotter sheets on wheels. . .;' . ' . 1 ' u j 24 oo mm diameter 12.00 mm dial ' .. '.. . . l . . z . . k' ' I j .' 1, l . given and should 'j ) '*

. ) .: I' ' ' ' matc.h the Wheels '.. ... .... . , . . . . . . , center drill b0th ends of spindle 'to be used . 'igure 9. 1 The external grindlhg splhdle for approximatelv loomm dlàm eter wheels. ) .

Fiqure 9.B Splhdle dim ensions. . ' î'''? '': ' '''. . t ,

42 . 143. .

' ' .. ?

8.00 mm8. 0 mm dia o .smm I ls

.c mm4. 00 mm dia

16.00 mm dia 20 mm* aa,oll mm ' diameter Ream 6.c mm '

Ream 12.00 mm . .

- 7 12 00 mm ' $. . .. . . . . . .. .. .. .S . .?, lo mm ) J

a mm ,. j . ..

''. .

'

7/23/2019 27 - Spindles


j.. . j è 7 X 1 threads . ' . P ulley groove to '

, . .' match your belt '', :5 mm diameter2igure 9 . 7 Pullev dimensions. . ,

. , Ream 8.o mm90.0 m m overall to stad. .. '

16.00 mm OD. - - - - - - - - - - - - - - - 12.00 ID ream ; . ,? . . .. . , .. , . .p .

. . I; . . , ,- 4 ))

' ' ' S text for Iength notes. ' , ' l 10 mm' ' ' ee,s . , . yt j . . .. . t . ' ' '

Figure 9.6 Bearing spacer dim ensions. ' '' ô.0Q mm . Figure 10.2 Spindle nose details and quill mounting recess.

and Figure 1 0.3 Cross section of rwo quill holding fixtures.1 (, .

. ' ' 2 Q- . q' C'''

.j . . , . ... , . ,. ' 1s ) 1 2 . 0 mm dia: 1 e,.. ., 7x 1 threads r .: .. .

. 6.35 Y j .5748 6.35 mm dia 6 . 00 mm dia to be

Key is 3.00 mm by 3.00 mm standard 12 X 125 nut C'Ollet closer 6 () mmbrass stock.Round as shown

Figure 9.8 Pulley nut dim ensions. xFigure 9.9 Kev dim ensions. F#/ to fitkevwaY DF hand. ' ' '

. z

; 100.00 mm housing ' .

38.00 mm ( Taper and reGes:ilS Of to match your R'his Slight Z.0 mm 1D.0 rnl'rlft;Ilets iocfease irlfbOf

. COdiameter must

mokllltirlg . . . . . - . - - - . . . l l match tNe. 3.18 mm reamed a n mm rmnmed '

slightty to deburr.i Wheels.raw ngs, Nx /

' ' ' see text for overall length considerationshis a rea must match the collets The spindle and drive are identical to the OD grinder pads ' d collet aoser that you will be anFigure 1 0.1 Cross section of ID pr/bt//hv splhdle.The parts of the solhdle shown above are iden- . tlsing with your spindle. Moto .. ' Dremel tool information is showntical to the OD gnhding splhdle. confirm uimensions

.' ' ' ê'C Figure 10.4 Cross section of qullls.

. . . . here.

1444

I za mm1 10.00 mm overall 7 mm 16 mm

1j '

1.7mm ' * l

j$J I. .. - - -1 - - - 32 mm 18 mm I' . jO P r

?. j$ j ' Thd28b10iIth

7/23/2019 27 - Spindles


$, j ' Thread 28 by 1.0 in Iathewo holes(,

4x0.7 clear I 12 mm. . , j38 mm diameter ,

: l :

Fi ure 1 1 . 1 Cross section across spindle. ) .t ywo oF THESE puv Es

' T dbottom plates. 50 mm ARE NEEDED.igure 1 2.4 op an110.00 mm

/ ... a .. t .;.'T . u j': :$a mm 12 mm r

.; :

.. ji Drill and tap 4X0.7 7 mm

. - . 4- - - - - - - - - - - - - - - - - - - 38.00 m dia . four places. - - - - -25 mm dia clearance hole '' 132 mm ja mm

: l.j

Recess to suit bearing ' The Iocation of this recess for. the mounting tang is to be

. 5 mm .....=ecess 1 mm deeper :; d etermined from your tool postthan bearing is thick and Iathe center height dimen-

''' ' . Figure 1 2.6 Back plate. sions.Sweat tang to this recess.

Figure 1 1 .2 Housing dim ensions. ,'

i ' ' '''., . . . 4 mm 2 mm.,, .. 1 y aa x 1 to match

S 1 E E '' ) / the threads in the top andverall Lengthzœo o mm to start E s E )CR 1 bottom platesv- m tn 16 mm dia . I match bearingeam 16 00 mm dia eter 50 mmdia

j4 - - - - = - - - - - - - - Ig , aearing 1

.. I 14 mm djalD=0.625. OD=0.750 i 1 ,, .L j '

j ' . jee text for information on spacer lengths - - - - - - - r - - - -. ' ..t 3 mm ,,

'

l j ot t .. 3 jjemsyot . a mm slot on other ' ' wigure 1 1 .4 Spacer dimensions. 6 mm for spanner side for wreoch '' .

j 'I ' Dimensions given are for 16 mm OD by 8 mm ID by 8 mm in . thick bearings . j6 mm ream ,

Figure 1 1 .B Pullev dlïnensions. 16 . 0 mmh ' Figure 1 2.7 Clamplbg nhgs - four are requlked (make them from the same stickl.;

14746 mm z vmm 1z.. mm.

... jo mm jz mm

j ''. 7 mm0 mm : o verall Iength =170 mm .check dim . Key recesssK. I - - - - - -Top bearing clamping . - - -

Iocation. Center of top #2 Morse Taperlate. 1Q.û mm hulet

. .ap 4X.07 . . .Thissectionandthesectionbelowit ''

7/23/2019 27 - Spindles


This section and the section below it - - - - - - -

I ia5 mm Gan be lomrn dia or 12 mm d :5 mm diameter 18 00 mm dia shaft 'depending on cutter size .ight On bearings ' '

.'

6 45 CI& diYmcter )1' *6' q$''' ' ' ' ' ':z , . g . r . rIEEEE .. .. ' . ; . ' .' '. 'i. . '' 7. ' ' - :'''.. ' ''. . , 7' ' '

, 31 .75 mm diameter :'. ... Z . . '

. , . s Vo eel cutter clamping 1 125 inch by 12 tpi '

. g Iocation. center in the frame . .. . E . . ..' ' ' ï' Figure 13 . 3 spindle dtmensions. , .

ï ' Make these registers and threads as Iarge ' -. .

@ . 1 10 c0 mm overall0 as possible depending on hole in the cutter . .

:.2- 2s mm Make stud from high strength screw . Loc-tite ' ' . ,, . into one side and screw into tlae other.

.''

. .,.

' '' '.

' ' '

.

' ' '

,

'

Zti Tap 4X . 07 k ' ' ' ' 'f ' :,' . rœ. 'i Bottom bearing clamping '' ) : r. J, . ,

'. . 8 x 1 taper 50 mm ' .. ' ' '

O Iotzation . center of bottom : ' . . oiI plug 38 mm djameter .' ' '' '' ' '

l plate. . ( . ) . ; .: hole thru . . ,r.. ,... .10 mm 5 . 't

j .' . à .....,.. .'q : ,.. ..Check dim . . .. . ..... ... v'.'..Ay . ''C ' Y' : ' ' tI , '

I Recesses to match the bearingsPulley to suit your cutter4 mm I and seals purchasedand driving tackle. . .

,,k' ' ..j '

Figure 1 2.9 Vertical section across splhdle parts (replace the rwo centre sections for ' j c mm 1 6 mmdifferent cutters). 50 mm dia .(,,c,..-,-'-----.-,.---,th , Key a by a mm

orto suit. ,,. vo suit belt

' j', l 25 mm dia .

. ja mm dia Rea 18 mm2 Morse taper

' 1I

' I' j

Staodard Myford Super 7 nose .' ' '' 50 mm diameter '. ' ' 5 l

. . . . Figure 1 3 . 5 Driving pullev dim ensions.igure 13.1 Sectlon across splndle wlth taper beanngs. Note that the need for seals moves thefront bearlhg farther lhboard /W thlb deslkn. '..vy.,t 149

Suggested American size Suggested British size Suggested metric size.'.

'

Thread Tap drill BA Ahread Tap drill M elric thread Tap drill (m m).

' j .'. ; 0.80 u4

A PPEN D IX 2 ' : 1.72 sa., . ' : ) .. ,. 2-64 50

, , ) 3.56 46 I ' . L 4.48 42 ' ' .' ' ' . ' ; ' ' '

; h , . . . . h fl .'.' ' ' '. . . . . . .r . 5 . . f . , 6 .44 37 'k I

7/23/2019 27 - Spindles


k .. . . . I . $ , . 6-40 33 '.. j tf 8.36 ig ,

'

# l 1 0-32 2 1 2 22 5 x 0.8 4.50 I nt ta I s ' ' ' 1 '' 12-28 '4 I a) . x-aa a xasy a 6 x 1 s.o, Ji. . . (

. . . . .?;', . ; ., ( .. t 5 6/6-24. l M6 BSF H 8 x 1 7 .0

, . t :S.; 4 Q :%- 2 0 W h P 1 0 x 1 2 5 8 . 7 0. . '( ' C ' '. . . . . , : ,, 76- 4. . . .' ..' ; ' , .'/ ' ,

'. ,

' i'.

.'.' . . . 7 1 , . . . . . ;: ,'. ): . ' , % -20 2%4 in. . ' X BSF Me in. 1 2 x 1 .2 5 1 0.80 '

Me-1 8 3V4 , . ...hi s table is provided as a reference for cal consideralion in the spindles qre- s , a au, ' 1 ' . ' -ghe builder. It Iists the main US threads sented. Fine threads are easier to cut (In a ' , j

n.

s nsjr 4.4 io. ' 1 8 x 1 5 , 6.50 - 1 6 :4 e .and indicates UK and metric equivalents Iathel than their coarse equivalents - this lao , , . , ./8- 1 4or the US threads suggested in this is especially true for Iarger thread sizes. It s . ,. 1 - 1 2 ?/'d' . ;- b ... ''.'. ' '. . .' . .''.' ' ' '' .ook. In m ost applications, thread sizes is not as im portant a consideration on a . F ,. ,. , 4 - 1 2 1 - A4 ' ' , . . .' ; . . .'. '' . .. . : . ' rare not critical and if the threads w ill fit sm all screws because their threads are ' 1 . . , , .1 W - 1 2 1 - 44 j . . . 7 .he space you have, the selection w ill be already fairly sm all and are best cut w ith ' .: . ., k. : r . Y8- 1 2 1 -39A4 '' . ' ' .

' ' . .adequate. Thread strength is not a criti- a thread die in any case. . 2.,

,4'

,j . , , . ' , % - 1 2 1 - ..

'.

' ' Unified National Coarse thread standard (UNC) , ' )

: 2-56 50. . ; J 3.48 47 ' '.

, h

, 4-40 43 , 6 43 3 x 0.5 2.65 I . . ' . , , 'I'. 5-40 38 6 ' 37 ' 3 x O.5 2.66 '

: .' . , ) g.g 2 g g ,' ;.f l. ... t . . . : . . ,1 $ . , ,' ') . '(' ' ' . . .?' 1J ' ,' '. .' 1.' ' ,j y ' 2 , r j :.,4 g 5

i ' ( ':J ' ' h ''T , I 2 12-24 1 6 @, ,)' , , '. r . '('I<. j ; .' .' ) . j<,.;g y , ; y j . , ; j

.

.:. . ï . . . . N - 1 8 F . ' : '.. . . . 'i ; . . . . .. .I 6 . . . .. . . t . ' $ ' . '' . . ' ?' ' . . ' I ' ' . . . ' . ' .' ' '. $' . '. ' 3A. 1 6 5/ e .$ : . . . . ' . ..' . . . . . . , . . . . ' . ' . ' . ' . . ' '( . y , , . 5 : ' ..' . . j.. .. ' '

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66 67 gtj g6 1 ()c doubje 34 cap f r f ront bearings 1 5. . .

'.. , . . anaerobic 64, 67 double sealed 86 carriage stop 107

.' ' ' :..r ' ' aluminium 38 front 13, 1 5, 17, 20, 25, cartridge spindles 3, 10, 46, ' . . '''

. . ï ' '' k free maotûnsng 63 2:, 31, 34e 39, *7, 4%, 47, 1 1 1, 1 21 ', .

'. . , anaerobic adhesive 87 49, 53, 56, 91, 1O6 design and construction

arbors 2, 9, 20, 62, 77, 82, nose end 1 4 castellations 31 . 35 .. $. .. , .;. :.,',..f'. ....? 2 .' r, ' .r : î . ' ' . 85 g 1 1 1 y . 1 g j 22 rear 1 5, 2O, 52 centre drill 1 20 .F z ; #

. .t g . 1 23, 131 sealed 1 5. 29. 70 centring buttons 42. 95, 1 24

. . t '. t ' ' clock 2 , selection of 14 Chaddock , Professor 70'

.' autom atic feed 1 27 .. spindle 7. 90 chuck 2, 1 3, 1 4, 18, 1 9, 20e. . .. , . . . auxiliary motor 1 0 ' sp ring Ioaded 70 2 1, 25, 26, 28, 29, 32. L , l .. ''

. .' axial Ioads 1 4, 1 6 tail end 14 . :. 33, 35, 40, 44, 46, 48,

'. axis 1 5, 20, 3% 33e 34, 44g taper 1 6 . ; $9, 59, 61, 73, 81e 84e' .. h . . r ; . . , ' . . . .' ' ' ''

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' 51, 6O, 1 1 1, 1 1 7, 1 22g tapered 3 ',.. 85e 90, 97, 108, 1 1 1,'' ' t ' 1 26 tapered roller 1O2 ' 1 1 7, 1 18e 1 1 9, 1 21,

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. back pulley 15 bearing catalogues 14 131'

.. ball bearing centre 21, 23 bearing seals 16, 33, 47, 61 chuck back plate 49 .o '' ball bearings 1, 2, 6, 9 , 49, belt drive arrangement 93 clam shell m ount 41 . .

k I ' 52, 83, 98, 105, 1O6 belt groove 33, 38 clam shells 46, 100 . . .

, . . ' sealed 92 block spacer 44 clam ping device 7. -. bar stock 32 bolt down jig 95 clamping plates 41 .

. k . basic milling 1 1 . bolt slots 53 . clam ping surfaces 29. basic spindle 10 bolts clam ps 7 . . à' : . . ' bearings 1, 3, 7, 8, 10, 1 3, mounting 6 . . clams 100, 107. 1 20

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.. .. : 1 4 , 1 s, 1 6, 20, 47, sa, boring 25, 28 clock cutters 2. ' ' ' ' ' ' 55, 58, 60, 64, 66, 67e boring tool 1 25 clock gears 1 3, 85e 92 , 1 1 3,

..? . . 7O , 74, 76, 78, 85, 88e brass 2, 38, 58, 76, 101, 1 1 6r '. 89e 92, 104, 107, 1O9 1 1 7, 1 21, 1 26 clock m aking 69e 92, 98 , .

angular contact 1 5 clock gears 1 16 1 16 .

. back 25, 39, 5% 55, 56y gears 94 clocks 1 2, 83

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t .' South Bend 3, 1 2 mist coolant systems 69 'let chuck 76 engineering 2 0D 1 16 . spindle 22, 38, 40, 1 1 9, M odel Englheer 1 2, 42e 1 13 needle bearings 9O z

Bet closers 2, 8, 9, 13e 36, draw ings and instructions 15 grinding spindle 72 ' :a6 1 29 model engineering applica- Nexus Plans Service 3o.9 58, 62, 83, 86, Drem el Moto 2, 59, 73, 77, tool-post mounted 77 rtical slide 13 tions 86 nose bearing 35 vea2 83

, 84 qrinding wheels 2 w ork 20 Morse 8 nose end bearings 14 . ;,ollets 2, 8, 9, 13, 19, 46, coltet closer 59, 62, 83 l ead shortness 59 , Morse tapers 33, 35, 36e 37, nose flange 629 83, 99, 109, 1 17, collet system nose 81 half m oon key 121 j eadloy 58 '

.'. 85, 103, 1O9 nose notes 19 '

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inding wheel arbor 83 headstock 20, 6O, 88, 1 24, jjtjajum grea se 109 ' collets 9 nose register 20, 21 ..'.24, 125, 126, 132 gr

,I 2 57 7 83 126, 127 d jal 7 1 5 ' ' . hole 36 nose threads 2 1 ;ome-made split 28 too . e . l oaax

7/23/2019 27 - Spindles


.oa , ax , , j .orse taper 9 wheels 1 13 high-speed grinding drive 1 10 j oad, radial 1 5 ,. . ' No 1 86e 91 nuts 7 ' , .' ' '

Myford 9 drill press 34, 1 20, 131 housing 6, 7, 13, 1B, 20, 23, j oading 7 ' No 1 spindle 85' ' 'it 30 drilling 21, 22, 25, 40e 1 1 8 24, 25, 26. 28e 33e 46, t oc-ute 59, 62, 87, 90, 96, No 2 13, 14 ,

1 5, 16, 19, oil seal 106. 108 .. ., .pts 2, 6, 8, 58 drive 53, 54, 55, 58. 61, 62e 1 oo 21

,as, a7, 46, 47, 48, overhead drive 1 1 3omponen

indle 1 6 high-speed 1 10 64, 67, 71e 75, 79' 8B, I ubrication 1 5 . . 7' 51, 56, 91, 104, 106 ' '''' .'''p.tandard 3 bigh-speed grinding 1 13 86, 87, 9O, 97, 102, ' u

o 2 collet 56 parting tool 90 ..

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compound slide 35, 92, / 14 milling 1 10 104, 106, 107, 1 09, machine shop 1 1 No 2 milling holders 38 parts 10 '...concentric rotation 25 overhead 1 1 3 ' ' 1 13, 1 1 7 hi niog 1 3, ,1 6, 1 9, 2o, No 2 spindle 46 sm all 2 t ' f3a/construction 13, 47, 58. 62 drive belt 1 5, 61, 1 1 1 block style 51 p.a :.4 a1, a6a a8, 4o, reamer 36e 37 garts fabrication 16 . ' .conversions 1 5 drive pulley 32, 33, 47, 6 1, outer 78 5..4 77 m otor photographs 3 .

'. '.oolant 1 1 3 67, 108 round 51' 54 . rough 23 hjgh-speed 1 13 pinions 2, 85 ' '8 '' 1 6 1 9 shaft m ounted 1 1 5 plate ,

m ild steel 41 '.;opper sequenc e .ross slide 13 , 38, 40. 43, electrical discharge mechining industrial applications 69 hi nistzs lavel 1 26 m otor drive 1 1 1 plate lhreads 22 .ac4 60 , 1 1 1, 1 13, 1 14, 1 22 industrial milling machines 7 j ninist's square 44, 51 m otor m ount 1 1 1 . plates, m ounting 14 ' ''''' .' maC 1 7, 1 20, 1 26, 1 28 end cutting mill 1 20 intefnal m orse taper 20 ' jf i cation 27, 29, 41, m otor pulley 1 1 3 . ' polyurethane belt 1 10 '.a gnross slide tabse J2O end m ill 1 B , 1 21 iron, soft 1 21 1 1 7 1 1 8 motors 1 1 1 puddling 59cutters 2, 7 mandrel 1 21, 1 24, 129 . m ount . pulleys 6, 1 3, 20e 23. 29,recision 2 face plates 19

, 20, 21 , 22, Jacobs chuck 69, 67 al compound feed 1 27 clam shell 41 32, 56 , 58, 61, 64, 67,anuutting gears 1 16 ' 24 , 48' 81e 94, 95, jigs, holding 80 marking blue 1 1 7, 1 18 m ounting 6, 2O, 43, 44' 46, 71' 7#, 84 , 86, 89' 93,utting Ioad 1 5 1 03

, 105, 1 06, 1 1 7 materials 2, 3, 6, 1 3, 1 4, 40, 94, 1 1 0, J / 3. 1 14, 98e 100, 101 , 104,utting tools 48 , 1 1 1 f iIe 25w 34, 41, 53, 60e 1 28 key stock 1 5 41 78. 1 1 .j 1 1 7, 1 2: 1 06 , 108, 1 09, 1 1 1, :.' .. #ylinders 45 filing 34 keyslot 34 free machining 2, 25e 58, m ounting bolts 6, 53 121inishing ream er 37 keyway 2O, 24e 33, 34, 48, ss mounting grid 6 commercial 33 ' ' .depth gauge 28 flange face 47 51 , 55, 71, 76, 90, . metric tooli ng 132 m ounting plates 3, 14 flanges 55esign 8

. 1 3 free machining steel 13 1O6e 108, 1 16, 1 21 micro spindse 2, 57 m ounting slots 6, 54 , grooves 33, 35, 38, 48emall spindle 8 front bearing cap 13 keyway cutting 40microm eter 18. 21. 28 m ountina studs 7 ' 55 , 62, 100, 109 .ial indicator 26 , 51, 75, 79, , mild steel plate 41 mounting tang 101 nuts 61 , 64, 67 . 26 e 1 28 gear cutting 1 16, 1 17, / /9 labyrinth seals 69 ilI h olders 2 m ountings 40 . slandard 33

. .mickson type 58 gear cutting frame 1 , 92 laminar air flow 70 mill shank 36.. Myford 46 '. .. ' '' stock 33 'i ital calipers 14 gear teeth 1 2 tathe 1 2

, 1 9, 20. 22, 33, 35, milling, basic 1 1 ' accessories 10

dim ensions 5, 13, 14 gearbox cover 129 40, 94 milling and grinding applica- chuck 83 quills 77 , 81, 82e 83' 84 ' '. i z '.. ' .mperial 3 , 8, 14 gears, brass 94 accessor es tj ons 6 collets 36 , 46, 74 spindle 77 .etric 4 George Thomas dividing head bed 1 3 . jjjj ng applications 32, 1 1 1 Iathe collets 58 quorn 75 .'l 3, 8, 14 120 carriage 1 10 . ijjing cutters 31e 34, 86, nose chucks 10 quorn tool grindef 70 'ivitjing bead 1 16

e 11:- : 19- gibs 1 :7, 1 21 centre height 44. : 1 1plates lo 131 grid 6 ' ' chu ck 1O, 33 ' a M ford S7-B 1 24 races 7, 1 5 , 58, 64 '

1 2 e holders 1 y6 1 19 1 29 mounting 6 '7 '' ' cross slide 1 3 , 34 1 q o u yford SB7 79 inner 7 , 17, 23. 29, 33.

dividing plate 1 . . m illing driveaki ng 1 16 grinder spindîe 79 culting lools 92 illi ng machine 10, 41e 53 spindle nose threads 1 3 34 , 47. 7O, 74, 9O'og 4.: ss - 88 Io 1 la '''''' Myford super 7 2. 3 ions 3 10 Myford Super 7 2 , 3, 8, 13e 106, 109 , . . , m illing operat .og driving plate 22 ' oo J 33 ' ' ' Mvford super 78 1 , 3, 5, . mijling spindle 7, 10, 12, 14, 99 , 104, 128 outer 7. 29, 33e 53 , 58,ouble pole sw itch 1 1 1 grinding ' ' 1 2r 1 1 1 tables and slides 6 64 , 66, 67, 75, 86, 9O,, j, j ,,jj . .,. r .). ,rawbar 85 e 88. 91 external 69 ' nose r a k) ds 1 3 Myford Super 78 l e 3, 5e 1 2 107, 1O9 . .,.: m isling 1 rea. ; , t .,. shears 6 1 1 1 7 ''raw ings 3, 5, 6, 8, 1 1, 1 3, ID 1 16 , 123 . . m isalignment 1 26 ' Myford system 42 racks 1 1 9 4 1 5

, 64 internal 69 ' ' ' Small 1 , 3 .

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. . , ) ê,. , ' .radial Ioads 15 Myford 6 thread cutting tool 82 1 . . . .. . . ' Ij : ,.ream ers 2 nose 6, 7, 14, 1 5, 1 9, thread flank 18 . . .' ' ' ' . ' '.'' ' .

M orse No 2 f inishing 1 5 22, 40, 46, 49, 64, 58, threading tool 23, 49, 50, . .. . .' . . ' ' . . .

reaming 1 1 8 59' 85, 104, 1 OB, 1O9 72, 82, 97e 106 1 ' b' 'recesses 53, 58' 62, 97, nose threads 1 3 threads 1 8, 23, 48, 50e 53,

1 00, 1 07 OD grinder 79 54, 72, 85, 88, 9 1, 93, '- 'i'

ring clam p 31 shaft 1 8, 33, 51, 97, 1O0 94, 95, 96e 97, 1 06, srisers 1 20 ' sizes 1 1 25, 1 27 ' ' .rotation threads 1 7 crow ns 1 8 .'

7/23/2019 27 - Spindles


. . y concentric 25 tool post grinder 69 ' cutting 2 / -jroughing reamer 37 using 1 16 external 1 7

, i 'ust prevention 34 . vertical 92 fine 2 / . ' A ' j ' spirit Ievel 1 26 internal 1 7, 7 1 I I1 , . : ., .safety 1 1 5 split collet 72 m ale 28, 71 ., . .

sealed bearings 1 5 . .' split plates 40, 43 m illing 13 ' 'seals square key 121 spindle 17 4u '

bearing 1 5 ' steel 58e 59' 71, 73 thrust bearings 9 j' ' fintegral 1 5 ' . free m achining 1 3, 20, tommy bar 81e 83

$ k .herline 86 . 24, 29, 37' 48, 51, 59e tools 2, 69, 85 .shop Iog 1 /&e 120 ' ' 78e 80, 81, 87, 89. 93, boring 80sketches 5, 6, 8 '.. 96, 1O6 high-speed precision 3 g . 'slots, mounting 6 .'' mild 1 24 thread cutting 22, 29, 30 'South Bend Iathe 3, 1 2 sheet 1 31 tool holder tang 94 (spacers 1, 4 /, 43, 58, 61, silver 94' 99, 324 tool post 51, 57, 69 .

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62, 64, 67e 71' 74, 75, studs 6, 7, 4O, 44 tool-post grinder spindles 1 13 -78, 86, 89, 1 20 mounting 7 tool-post mounted grinder

spanner notches 37 swarf 1 5, 31, 53, 98 1 22 ;spanner slots 55 sw ivelling vertical slide 44 tool-post stud 1 01 'i ' ispigots 1 20 tooling 2, 85 E : '

Spindles 10 ' T nuts 40, 44, 1 20 metric 132 'assem bly 20 T slots 47 total indicated runout 24 1cartridge 2, 3, 10, 1 1 1, tail end bearing 14 turning skills 1 2

1 2 1 tailstock 2O, 2 1, 22. 23, 25, -j '-clamped bearing 2 33 34 35 37 49 52 urethane belting stock 84 1 ' 'components 1 6 53, 59, 60, 62, 75, 82, j .construction 2, 3 83, 88, 104, 105, 1 06. ''V'' belt 89 ''.''' ' 'design 5, 1 4 . 1O9e 1 24e 1 26 'zV'' belting 84 1driving 45 : ' ''' tapers 2, 8, 1 27 vertical slide 1 3, 34 , 38e 40, 1f ce 23 M orse 2 43, 44 , 47, 48, 55e 72, 'flange 23, 31 E . . M orse No 1 8 92s 1 1 1, 1 13, 1 1 7, 'front cap 29 M orse No 2 2, 8 1 18, 1 1 9 , 120. 12 / Egrinding 1 , 2, 69, 72 taper bearings 1 5 vertical spindle 92 t 'high speed 1 3, 32 taper collets vice 34 j 'housing 14, 15, 24, 26, Morse No 2 8 î ' ' k '

27, 29, 30, 33, 47 tapered bearings 3 wheel cutting 1 1 ''' ' ' .industrial 25 tellurium 58 wheels 2 '' . . ' - 1 'zmicro 2, 57 Thom as, George 57 w hite Iithium 34 1 ,

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milling 1. 7, 10 dividing head 57, 82, 120 W ilding, John 1 2 , 99 t . .Morse No 1 taper 85 Thornton 99 Woodruff key cutter 1 21 t j .

orse No 2 taper 46 thread cutting 1 26 ' j .. ' 'mounting 2, 40 thread cutting screw 1 22 . 1 k -

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Date post:	18-Feb-2018
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27 - Spindles

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